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Aspen simulation of Biodiesel production plant

Technical Report · March 2015

DOI: 10.13140/RG.2.1.2154.9204

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1

PRODUCTION OF BIO-DIESEL FROM

SESAME OIL USING ASPEN SIMULATION

A project report submitted in partial fulfillment of the

Requirements for the award of the degree of
Bachelor of technology in chemical engineering by
SUMANTH VINAY KUMAR B A V KRISHNAM RAJU
(Y11ACH448) (Y11ACH402)
K RAJENDRA S SARATH CHANDRA
(Y11ACH424) (L12ACH467)

UNDER THE ESTEEMED GUIDANCE OF

Mr. M V RATNAM M. Tech
Assistant professor
DEPARTMENT OF CHEMICAL ENGINEERING
BAPATLA ENGINEERING COLLEGE BAPATLA-522101

DEPARTMENT OF CHEMICAL ENGINEERING

BAPATLA ENGINEERING COLLEGE
BAPATLA

Production of Biodiesel 1
2

CERTIFICATE
This is to certify that project entitled “PRODUCTION OF BIO-DIESEL FROM
SESAME OIL USING ASPEN SIMULATION” submitted by Mr.SUMANTH VINAY
KUMAR B, A V KRISHNAM RAJU, K RAJENDRA, S SARATH CHANDRA. In partial
fulfillment of the requirement for the degree of BACHELOR OF TECHNOLOGY IN
CHEMICAL ENGINEERING and is a bonafied of the work carried out by them during the
academic year 2013-2014.

Mr. M V RATNAM M. Tech, Dr. J S RAO M .Tech, Ph .D,

Asst. Professor Professor& Head of department
Department of Chemical Engineering, Department of Chemical Engineering,
Bapatla Engineering College, Bapatla Engineering College,
Bapatla-522101. Bapatla-522101.

Production of Biodiesel 2
3

ACKNOELEDGEMENT
We are extremely happy to present this report of project work under the guidance of
Mr. M VENKATA RATNAM, Assistant professor, Department of chemical engineering,
Bapatla Engineering College. We would like to express our deep sense of gratitude for the
valuable guidance and attention given by him during the course of this project work.
We would like to express our sincere thanks to Dr.J.S.Rao, Prof&Head of Chemical
Engineering Department for his encouragement and providing the necessary facilities.
We would like to express our sincere thanks to Dr. SASIDHAR K KUDARI,
Principal, for giving us permission to carry out this project work in the college and providing
the necessary facilities.
Special thanks to all who helped us directly or indirectly during the course of this project
work.

By
SUMANTH VINAY KUMAR B
A V KRISHNAM RAJU
K RAJENDRA
S SARATH CHANDRA

Production of Biodiesel 3
4

ABSTRACT

Fast depletion of world’s petroleum reserves and increasing ecological Concerns has
created a great demand for environmentally benign renewable energy resources. Biodiesel has
emerged as a sustainable alternative to petroleum origin diesel and its usage have been
encouraged by many countries.Transesterification reaction is the most common process to
produce biodiesel from variety of vegetable oils and animal fat. Tran’s esterification process
depends upon a number of process parameters which are required to be optimized in order to
maximize the biodiesel yield.

Plant oils have quite high viscosity compared to diesel fuel. These can be used as
alternate Fuel to run a diesel engine but this creates problems of injector coking, dilution of
engine oil, Deposits in various parts of engine during extended operation of the engine.
Esterification of these Oils reduces the viscosity to a large extent by converting the oils to
bio-diesels. This paper deals With the effect of various parameters on yield and conversion of
oil to biodiesel prepared fromRefinery waste oil. Molar ratio of 6:1 gave very good
conversion and yield of the bio-diesel for reaction. Time of 4 hrs but for a reaction time of 6
hrs, molar ratio of 4:1 was equally good. Percent conversion was almost same at different
reaction temperatures. However, percent yield decreased with decrease in reaction
temperature. High FFA content in oil affected the bio-diesel yield and the effect was more
evident at low reaction temperatures.

Production of Biodiesel 4
5

CONTENTS

1. Introduction
1.1 Literature survey
1.2 Uses and Applications
1.3 Properties

2. Problem Statement

3. Process Selection

4. Reaction

5. Process flow sheet

6. Mass & Energy Balance

7. Design of shell and tube heat exchanger

8. Design of distillation column

9. Plant location and layout

10. Bibliography

Production of Biodiesel 5
6

BIO DIESEL

1. INTRODUCTION

LITERATURE SURVEY

Diesel fuel is extensively used in heavy trucks, derived from rapeseed, soybean, palm,
sunflower, city transport buses, locomotives, electric generators, coconut, linseed, etc.
However, in India, it is not farm equipments, underground mine equipments and viable to
produce biodiesel using such edible oil to plays an important role in the economy of India.
Produce biodiesel because of a big difference in demand various forms of gaseous, liquid and
solid pollutants and supply of edible oils. In this context, crops that from diesel engine can
endanger human health and can produce non-edible oils such as Jatropha, Karanja, damage
the ecological environment. Petroleum reserves and environmental consequences in
substantial quantities can be grown in large scale on of exhaust gases from diesel fuelled
engines are some of non-cropped waste lands.

At current production levels, biodiesel requires a subsidy to compete directly with petroleum-
based fuels. However, Current production levels are 20–25million gallons/year, but achieving
current production levels of 500 million to 1 billion gallons/year should be feasible. The
combined vegetable oil and animal fat production in the India totals about 35.3 billion pounds
per year. This production could provide 4.6 billion gallons of biodiesel.
However, the annual consumption of diesel fuel is about 33 billion gallons. If all of the vegetable oil
and animal fat produced in The India were available to produce biodiesel, it would only displace
about 14% of the current demand for Onhighway diesel fuel.

1. Bio-Fuels

1.1 Classes of bio fuels

Bio fuels fall into three classes:

The first class is material produced for the fuel production, energy plantation, and bi-
products of other agricultural activities and materials that could be classified as wastes. The
economics of using such fuels depend on which class the fuel belongs to.

Production of Biodiesel 6
7

The second class fuels that are produced as processing bi products, offer better
economic opportunities. Baggase, Sawmill refuse, Rice husk etc. are also used as fuels.

The manufacturing process leading to their creation produces a concentration of

material is still valuable because of its immediate availability. The drawback with some of
these fuels is that they are produced on a seasonal basis.

The third class bio fuels include materials that have only marginal fuel value, and may
have a negative useable energy potential. These materials often require a considerable energy
input into their collection and processing. Their use as a fuel is dependent on other benefits
such as environmental hazard production being the primary reason for collection and
combustion.

1.2 Biofuels and the environment

When biodiesel is burned the exhaust gases does not contain sulphur oxides and sulphates.
Criteria pollutants are reduced with the use of biodiesel. Sulphur emissions are essentially
eliminated with pure biodiesel.

Tests show the use of biodiesel in diesel engines results in substantial reductions of
unburned hydro carbons, carbon mono oxide, and particulate matter. Emissions of nitrogen
oxide stay the same or slightly increased.

Carbon monoxide

The exhaust emissions of carbon monoxide from biodiesel are on average 47% lower
carbon monoxide emissions from biodiesel.

Particulate matter

Breathing particulate has been shown to be a human health hazard. The exhaust
emissions of a particulate matter from biodiesel are about 47% lower than overall particulate
matter emissions from diesel.

Hydro carbons

The presence of hydrocarbons in the exhaust emissions are almost reduced when
biodiesel is used.

Production of Biodiesel 7
8

Nitrogen oxides

Nox emissions from biodiesel increase or decrease depending on the engine family
and testing procedures. Nox emissions from pure biodiesel increase on average by 10%.
However, biodiesel with lack of sulphur allows the use of Nox control technologies that can’t
be used with convectional diesel. Additionally, some companies have successfully developed
additives to reduce Nox emissions in biodiesel blends.

Biodiesel reduces the health risks associated with petroleum diesel

Biodiesel emissions show decreased levels of Polycyclic aromatics Hydrocarbons, which

have been identified as potential cancer causing compounds in health effects testing, PAH
compounds were reduced by roughly 50%.Targeted NPAH compounds were also reduced.

Dramatically with biodiesel, with 2-nitri fluorine and 1-nitro pyrene reduced to only
trace values.

Successfully alternate fuels fulfill environment and energy security needs without
sacrifying operating performance. Operationally, biodiesel performs very similar to low
sulpur diesel in terms of power, torque without major modifications of engine or
infrastructure. Biodiesel offers a similar power to diesel fuel.

One of the major advantages of biodiesel is the fact it can be used in an existing
engine as the fuel ingestion equipment with little impact to operating performance. Biodiesel
has a higher cetane number than diesel fuel. In over 15 million miles in field demonstrations
biodiesel showed similar fuel consumption, horse power, torque and mileage rates as a
convectional diesel fuel.

1.3 Biodiesel and India

India imports more than seventy percent of the crude oil. This is an incredible
dependency on foreign oils and an alternate should be found and the cultivation of bio crops
could be taken up to serve two major objectives. Firstly with proper selection of low nutrition
demanding oil bearing species, the waste land can be brought under compact plantation.
Secondly, rejuvenation of the waste land can also be achieved by upgrading the soil quality
by addition of seed meal, which is obtained after extraction oil that has a high nutrition value
India has a tropical advantage and several species capable of giving oil bearing seed are

Production of Biodiesel 8
9

known to grow. India can produce about 4-5million tonns per annum of biodiesel, which is
10% of current diesel demand.

1.4 Indian energy scenario

India faces more problems that just need for reliable energy supply. Even if the
environment is able to acquire rights to natural gas and crude oil supplies all around the
world, the problem does not end there. India faces a major shortage of refining capacity. As a
result prices of diesel, petrol, kerosene can go through the roof even if the crude oil price
moves up slowly.

The refineries all around India are old and mainly acquired from the Soviet Union
many years back. They need to be replaced soon. They operate at a much lower capacity due
to maintenance needs and cause bad pollution all around.

Oil accounts for about 30% of India’s roughly 5.4 billion barrels in oil reserves are
located in the Mumbai high, upper Assam, Cambay, Krishna-Godavari and kaveri basis. The
offshore Mumbai high field by far India’s largest producing field with current output of
around 260,000 barrels per day.
India’s average oil production level for 2003 was 819,000bbl/day of which
660,000bl/day was crude oil. India had net oil imports of over 1.4 million bbl per day in 2003.
Even with these new reserves, India domestic natural gas supply is not likely to keep pace
with demand and country will have to import.

In such a situation, only renewable sources like bio fuels can answer the current
demand. There is an urgent need to realize the importance of fuel like biodiesel and take
measures to bring them in to vague.

1.5 What is a bio fuel?

BIO FUEL is any fuel that derives from bio mass, recently living organisms or their
metabolic by products, such as manure from cows. It is a renewable energy source unlike the
other natural resources such as petroleum, coal and nuclear fuels. The carbon dioxide by
growing plants, so burning it does not result in a net increase of carbon dioxide in Earth`s
atmosphere. As a result, biofuels are seen by many as away to reduce the amount of carbon-

Production of Biodiesel 9
10

dioxide released in to the atmosphere by using them to replace non-renewable sources of

energy.

There are three classes of bio fuels:

1. Solid bio fuels:

Wood
Straw
Animal wastes
2. Liquid bio fuels
Bio alcohols
Biologically produced oils can be used in diesel engines.
Straight vegetable oils (SVO)
Waste vegetable oil (WVO)
Biodiesel obtained from trans-esterification of animal fats, vegetable oils.
3. Gaseous bio fuels
Methane

Wood gas
1.6 What is biodiesel?

Biodiesel is the name for a variety of a ester based fuels (fatty esters) generally
defined as mono alkyl esters made from vegetable oils such as soybean oil, canola oil (or)
hemp oil (or) sometimes from animal fats through a simple trans-esterification process.

Biodiesel burns clean which results in a significant reductions of the types of

pollutants that contribute to smog and global warming and emits up to 85% fewer cancer
causing agents.

1.7 History of biodiesel

The concept of using vegetable oil as an engine fuel dates back to 1895 when Rudolf
Diesel developed the first engine to run on peanut oil, as demonstrated at the world exhibition
in Paris in 1900. Unfortunately, R.Diesel died in 1913 before his vision of a vegetable oil

Production of Biodiesel 1
11

powered engine was fully realized. There is documentary recording that biodiesel trans-
esterification technology experimentation was first conducted as early as 1853 by scientists E.
Duffy and J. Patrick, many years before Rudolf’s diesel engine became functional. After
R.Diesel death the petroleum industry was rapidly developing and produced a cheap
byproduct diesel fuel “powering a modified diesel engine”. Thus, clean vegetable oil was
forgotten as a renewable source of diesel. The first public recognition of trans-esterification
technology became a patent asset on 31st august 1937 when G.Chavanne of the University of
Brussels was granted a patent license for alcholysis of vegetable oils using ethanol or
methanol with the purpose of separating the fatty acids from the glycerol by means of
replacing glycerol with short linear alcohols. It was the earliest account of the production as
well as the terminology “biodiesel”.

Today’s diesel engines require a clean–burning, stable fuel operating under a variety of
conditions. In the mid 1970’s fuel storage spurred interest in diversifying fuel resources and
thus biodiesel as fatty esters was developed as an alternate to petroleum diesel. Later in
1990’s, interest was raising due to the large pollution reduction benefits coming from the use
of biodiesel. The use of biodiesel is affected by the legislation and regulations in all countries.
On February 9, 2004 the government of Philippines directed all of its departments to
incorporate 1%by volume coconut biodiesel in diesel fuel for use in government vehicles.

On Oct 27, 2003 in United States, by 1995 10% of all federal vehicles were to be using
alternate fuels to set an example for the private automotive and fuel insides. Several studies
now funded to promote the use of blends of biodiesel and heating oil. In USA soybean oil is
the principle oil being utilized for biodiesel.

Biodiesel is defined as the esters of long chain fatty acids. Biodiesel is a renewable and
biological source that has been receiving more attention all over the world due to the energy
needs and environmental consciousness. Biodiesel is mono-alkyl esters of long chain fatty
acids, which falls in the carbon range C12-C23.

Biodiesel is an alternative fuel for diesel engines that is produced by chemically reacting a
vegetable oil or animal fat with an alcohol such as methanol. The reaction requires a catalyst,
usually a strong base or an acid and produces new chemical compounds called methyl esters.
It is these esters that have come to be known as biodiesel.

Production of Biodiesel 1
12

PROPERTIES OF BIODIESEL
C o m m o n n a m e B i o d i e s e l

C o m m o n c h e m i c a l n a m e Fatty acid (m)ethyl ester

C h e m i c a l f o r m u l a r a n g e C14 –C24 methyl esters

2 3 . 3 - 5 . 2
Kinematic viscosity range (mm /s, at 313
K)
3 8 6 0 - 8 9 4
Density range(kg/m , at 288K)
B o i l i n g p o i n t r a n g e ( K ) > 4 5 7

F l a s h p o i n t r a n g e ( K ) 4 2 0 - 4 5 0

Vapor pressure (mm Hg, at 295 K) < 5

D i s t i l l a t i o n r a n g e ( K ) 4 7 0 - 6 0 0

S o l u b i l i t y i n w a t e r Insoluble in water

P h y s i c a l a p p e a r a n c e Light to dark yellow, clear liquid

O d o r Light musty/soapy odor

B i o d e g r a d a b i l i t y More biodegradable than petroleum diesel

R e a c t i v i t y Stable but avoid strong oxidizing agents

Production of Biodiesel 1
13

Uses and applications of bio-diesel:

Some of the advantages of using biodiesel as a replacement for diesel fuel are:

ß Renewable fuel, obtained from vegetable oils or animal fats.

ß Low toxicity, in comparison with diesel fuel.
ß Degrades more rapidly than diesel fuel, minimizing the environmental consequences
of biofuel spills.
ß Lower emissions of contaminants: carbon monoxide, particulate matter, poly cyclic
aromatic hydrocarbons, aldehydes.
ß Lower health risk, due to reduced emissions of carcinogenic substances.
ß No sulphur dioxide (SO2) emissions.
ß Biodiesel is plant-based and adds no CO2 to the atmosphere.
ß The ozone-forming potential of biodiesel emissions is nearly 50% less than
conventional diesel fuel.
ß Biodiesel is environmentally friendly: it is a renewable energy.

Problem statement

To produce 213.456 tons/day of biodiesel using sesame oil by alkaline transesterification by

using Aspen simulation

Biodiesel Production Methods:

1 Alkaline Catalyzed Trans esterification Process

2 Acid Catalyzed Trans esterification Process
3 Acid-alkaline Catalyzed (Two Stages)
4 Non Catalyzed Supercritical Trans esterification Process
5 Enzyme Catalyzed Trans esterification Process

Selection of Process:

• Alkaline Trans esterification process is selected to produce biodiesel because it

requires less time and it can gain higher yields.

Production of Biodiesel 1
14

• This process is most effective for feedstock with FFA level below 2% as it is reported
to proceed about 4000 times faster than acid catalyzed esterification process.
• Base catalysts such as sodium methoxide, sodium hydroxide, and potassium
methoxide potassium hydroxides have been successes fully used at industrial level for
the production of bio diesel.
• It becomes ineffective when free fatty acid level exceeds 2% because FFA reacts with
the most common alkaline catalyst and forms soap which inhibits the separation of
ester from glycerin.

Trans esterification:

• Trans esterification is the process of exchanging the organic group R″ of an ester with
the organic group R′ of an alcohol.

Model The process was modeled in Aspen to determine optimal conditions to maximize the
conversion of vegetable oil to biodiesel.
Vegetable oil is a complex solution which was represented as triolein in the simulation.
Biodiesel was represented as methyloleate. Triolein is reacted with methanol to produce
methyloleate and glycerol according to the reaction below.

Production of Biodiesel 1
15

The process model involved two R Gibbs reactors operated in series, as shown in the process
flow sheet below. Triolein (FEED-OIL) and methanol (FEEDMET) were fed into the first
RGIBBS reactor (R1) in stoichiometric amounts. The outlet of this reactor (R1-OUT) was
separated in a flash drum (R1-FLASH) to remove unreacted methanol (METOH-R1) to be
passed to the second reactor. The two phase liquid leaving the first flash drum (PROD1) was
then separated in a decanter into glycerol (GLYC1) and a mixture of the unreacted triolein
and biodiesel (R2-FEED). The triolein-biodiesel mixture then entered the second R Gibbs
rector (R2) with recycled methanol (REC-MET).
The second reactor product stream (R2-OUT) was then flashed to remove and recycle
methanol (METOH-R2), this stream split (RECSPLIT) to allow a purge stream (PURGE).
The bottoms liquid (PROD2) was decanted (DECANT2) to separate the biodiesel
(BIODIESEL) and glycerol (GLYC-2). The glycerol streams were combined (GLYC-MIX)
to produce the final glycerol product as a process output. An overview of the process can be
seen in the Figure 1: Biodiesel production process flow sheet Figure 1 below.

CHALLENGES
Property Estimation Vegetable oil is a mixture of triglycerides extracted from plant matter;
these molecules are derived from glycerol and three long-chain fatty acids. These fatty acids
vary widely in length and degree of saturation and so their properties vary as well. Triolein
(CAS 122-32-7) is a vegetable oil unique in that all of its fatty acid groups are the same, oleic
acid. It has been shown to make up 4-30% of olive oil (Thomas, 2002). Triolein was chosen
to represent vegetable oil in the process so the transeterification process had only two
products, glycerol and methyl-oleate. Triolein has been used as a vegetable oil analogue in
several case studies and process optimizations of biodiesel production plants (West, Posarac,
& Ellis, 2007) (Mueanmas, Prasertsit, & Tongurai, 2010) (Dhar & Kirtania, 2009).

Production of Biodiesel 1
16

Although the properties for triolein were available in the ASPEN data banks, an error arose
when trying to run the model (see Appendix B: Missing Property Parameters). Ideal gas heat
capacity data for Triolein was missing and could not be determined through property
estimation. Values for ideal gas heat capacity were manually entered; the pure-component
data came from the work of Noor et al. (Noor Azian Morad, A.A. Mustafa Kamal, F. Panau,
& T.W. Yew, 2000). The pure component and mixture properties were re-estimated using this
data. The property data setup is shown in Figure 2 below.

Figure 2: Ideal gas specific heat data used to re-initialize property estimation for Triolein
Once the ideal gas heat capacity data had been entered and the properties reestimated the all
input specifications were translated and the simulation generated results.
Convergence
ASPEN uses flowsheet convergence blocks to solve iterative calculations arising from
recycle or tear streams and design specifications. The blocks determine how guesses for
recycle streams and design spec variables are updated from iteration to iteration.
Convergence can be manipulated in ASPEN by changing the tolerance, algorithm, or the

Production of Biodiesel 1
17

maximum number of iteration steps (Sup Yoon & Kim, 2011). The process taken to converge
the simulation will be discussed here.
Originally, the model was designed so all unreacted methanol was returned to the frontend of
the process (see Appendix E: Proposed Process Flow sheet). There was no purge stream
specified so at steady state there was a hold-up of methanol in the process. This generated a
convergence error in the
methanol recycle stream, as every iteration would return a higher value than the time before.
The error generated in the simulation control panel is shown in Figure 3 below.

Figure 3: Convergence solver error report generated in simulation control panel

The error was initially fixed by adjusting the Convergence options. It was believed that the
error was caused by the complex system of recycling reactants from three points in the
process. The tolerance was increased from .0001 to .001 and the simulation run again. The
model would not converge after 30 iterations, the default number, so the maximum number of
iterations was increased to 500. This meant the process was undertaking a maximum of 500
calculation loops to converge the model to within 0.1%.
The simulation was converged to <0.099% error within ~80 iteration. While this appeared to
solve the problem it did not address the underlying process error. Upon investigating the
stream results it was determined that methanol was building up in the process without an
adequate purge stream. The design was revised to include a stream splitting block to purge
%10 of the methanol coming from the second reactor flash drum. The convergence options
were reset to default, 0.01% tolerance and 30 iterations, and the simulation was reinitialized.
With the purge stream in place the simulation was capable of producing results without
warnings or convergence errors.

Production of Biodiesel 1
18

PROCESS STEPS:
Heating of Oil:

• In order to speed up the reaction, the oil must be heated. The ideal temperature range
is 50º C to 60º C.

• Proportion of Sesame oil, Sodium Hydroxide (alkali catalyst) and Methanol taken are
as follows: 1 : 6
Mixing of Methanol and catalyst:
• The purpose of mixing methanol and the catalyst (NaOH) is to react the two
substances to form methoxide.

• Firstly, NaOH is mixed slowly with alcohol in a three-necked round bottom flask,
stirring continuously.

• NaOH does not readily dissolve into methanol. It is best to turn on the mixer to begin
agitating the methanol and slowly pour the NaOH in.

• When particles of NaOH cannot be seen, the methoxide is ready to be added to the oil.
This can usually be achieved in 20 –30 minutes.
Heating and mixing:

• Oil is poured slowly in the prepared Sodium methoxide mixture with continuous
stirring and then heated at 50-60 °C for about 90 minutes.

• A magnetic stirrer works fine as a mixer. Too much agitation causes splashing and
bubbles through vortexing and reduces mix efficiency. There should be a vortex just
appearing on the surface.

• Adjust the speed, or the pitch or size of the stirrer to get the right effect. The
Transesterification process separates the ethyl esters from the glycerin. Now the
whole system should be cooled and the mixture allowed settling for at least 12 hours.

Settling and separation:

• The ethyl esters (biodiesel) will be floating on top while the denser glycerin will have
congealed on the bottom of the container forming a hard gelatinous mass. Then
carefully decant the biodiesel.

• The semiliquid glycerin has a dark brown color and the biodiesel is honey colored.
• The separated layer of Biodiesel is then fed to a batch distillation unit for the recovery
of ethanol and water. The temperature is maintained around 105 °C. The impure
Biodiesel is washed with water. Two layers are formed, upper layer being Biodiesel
and the lower layer being water.

Production of Biodiesel 1
19

• Now the Biodiesel is separated from the water by a separating funnel. This Biodiesel
may contain a small percentage of water and so it is then dried by passing through
silica gel.

Overall Material Balance

Transesterification reaction is the reaction to produce bio diesel from tri glyceride.

Refinery waste has the composition like:

- Palmitic acid
- Stearic acid
- Linoleic acid

But it mostly contains of Oleic acid of about 51.6% so we show

the balance for this compound.

Molecular weight of oil=C57H104O6

= (60*12) + (101*1) + (6*16)

=917 wt units

Molecular weight of methanol=CH3OH =32 wt units

Molecular weight of bio diesel=CH3OCOC18H34

= (20*12) + (37*1) + (2*16)

=309 wt units

Molecular weight of glycerol=C3H8O3

= (3*12) + (3*16) + (8*1)

=92 wt units

Production of Biodiesel 1
20

B l o c k I n ( K g / h r ) O u t ( k g / h r ) Relative Difference

M I X E R 1

3757.67149 3 7 5 7 . 6 7 2.42036778E-16

M I X E R 2 12612.1631 1 2 6 1 2 . 2 2.15501016e-12

H E A T 21466.6547 21466.6547
EXCHANGER

C S T R 12612.1631 1 2 6 1 2 . 2 -1 .87 49 25 19 e- 14

DISTILLATION COLUMN 12612.1631 12612.1629 1.23652039e-08

P U M P 1 0 7 7 7 . 0 2 1 1 0 7 7 7 . 0 2 1 3.37568127e-16

SEPARATOR 1 0 7 7 7 . 0 2 1 1 0 7 7 7 . 0 2 1 -1 .68 78 40 63 e- 16

DISTILLATION 9856.07386 9856.07386 -1 .84 55 51 72 e- 16

COLUMN

Production of Biodiesel 2
21

ENERGY BALANCE

Here we are doing the energy balance for the following systems:

Heat exchanger=1

Distillation column=2

Continuous stirred tank reactor=1

MIXER

Production of Biodiesel 2
Heat Exchanger

Heat duty = 629669.37 J/sec

CSTR

DISTILLATION COLUMN 1

Aspen Simulation Biodiesel Plant Page 23

SEPARATOR

Aspen Simulation Biodiesel Plant Page 24

DISTILLATION COLUMN 2

DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Shell side:

• Mass flow rate of process fluid= 3.62 kg/sec

• Average cp= 2767.8 J/kg-K
• Density = 750 kg/m3
• Viscosity = 0.00252 kg/m-sec
• Thermal conductivity = 0.01375 W/m-K
• Inlet temperature = 473.15 K
• Outlet temperature = 416.85 K

Tube side:

• Mass flow rate = 2.45 kg/sec

• Cp = 1920 J/kg-K
Aspen Simulation Biodiesel Plant Page 25
• Density = 880 kg/m3
• Viscosity = 0.00934 kg/m-sec
• Thermal conductivity = 0.0607 W/m-K
• Inlet temperature = 300.15K
• Outlet temperature = 423.15 K

3. Assume Uo = 500

S
Ft = 0.94 (from graph 12.19, Kern)

∆Tm = ∆Tlm * Ft = 77.49 *0.74 = 57.7

A= = 21.96 m2

5. Out Side Diameter = 19.05 mm

Internal diameter = 15.05 mm
6. Tube length = 3.66m
7. no of tubes = 99.32 tubes

8. Tube velocity =
= 3 . 1 7 m / s
R e = 4 4 5 6 . 4 Pr = 294.16

1.

hi = 2190.05 w/m2k

9.ΔPt = Npass {8jf*(L/di)+2.5} ρu2/2

= 4{8*1.2*10ˉ³(3.66/15.05*10ˉ³)+2.5}*(880(3.17)2/2)

= 0.233bar

10. Db = do ( Nt / Kt )1/n

Aspen Simulation Biodiesel Plant Page 26

= 19.05*10ˉ³ (
= 0.287 ds = db + C
(clearance = 55mm)
=0.287+0.055 = 0.342m

lb = Ds/5 = 0.0684m

Pt = 1.25 do
= 1.25*19.05*10 = 0.0238m

De ]
De = 0.0139 m

Nu = 0.023* Re0.8 * Pr0.33

q=

2.45* 1920 * (150-30) = ṁ* 2767.8*(200-143.7)

ṁ = 3.62 kg/sec

Q = 3.62*10¯³ m3/s

Ct = Pt – do

= 0.0238 – (19.05*10ˉ³) = 0.00475 m

Ashell = C * lb ds/Pt
= 0.0046 m2

Ũs = 1.01 m/s

Re

Pr
Baffle cut = 25%
ho = 0.023* Re0.8 * P ˙³³
= 0.023*(4202.40)0.8* (51.09)0.33

ho = 1572 w/m2 k

Aspen Simulation Biodiesel Plant Page 27

∆Ps = 8* jf *

f= 4.1*10ˉ3

)
= 3.0 bar

Rdo + Rdi
kw = 19 w/m k

Therefore, Uo = 470.6W/m2 K

Now = 500 – 470.6/50

=0.0588
= 5.8 % < 30%
Hence design is accepted.

Design of distillation column

Process design of distillation column for the separation of Bio diesel and methanol is given
as below. Feed entering the column consist of bio diesel and glycerol mixture. Boiling points
of the compounds entering the column at operating pressure i.e. one atmospheres.

q Bio diesel 135˚C

q Methanol 64.7 ˚C
Procedure to design the distillation column:

1. Calculate the maximum and minimum vapour and liquid flow-rates, for the turn down
ratio required.

2. Collect, or estimate, the system physical properties.

3. Select a trial plate spacing.
4. Estimate the column diameter, based on flooding considerations.
(a) Using Actual velocity, calculate the value of volumetric flow rate vapour, at the
bottom, then find net area , column C/S area and downcomer area and length of weir.

5. Calculate the value of perforated plate area.

6. Then find the area of distribution and calming zone (Acz).
7. Now find out total hole area, weir height and check for weeping.
Aspen Simulation Biodiesel Plant Page 28
8. The check for weeping is found by estimating the values of
(a) head loss through dry hole (hd)
(b) head loss through bubble formation (hσ)
(c) height of liquid crest over weir (how)
(d) From value of (how+hw) & (Ah/Aa ) we get minimum value of (hd+hσ)min
(e) Now find out whether the design value is greater than theoretical value or not.
9. Now check for down flow flooding.
10. Calculate the maximum and minimum vapour and liquid flow-rates, for the turn down
ratio required.

11. Collect, or estimate, the system physical properties.

12. Select trial plate spacing
13. Estimate the column diameter, based on flooding considerations.
14. Decide the liquid flow arrangement
15. Make a trial plate layout: downcomer area, active area, hole area, hole size, weir height
16. Check the weeping rate if unsatisfactory return to step 6.
17. Check the plate pressure drop,if too high return to step6 18. Check downcomer back-up, if
too high return to step 6 or 3.

19. Decide plate layout details: calming zones, unperforated areas. Check hole pitch, if
unsatisfactory return to step 6.

20. Recalculate the percentage flooding based on chosen column diameter.

21. Check entrainment, if too high return to step 4
22. Optimise design: repeat steps 3 to 12 to find smallest diameter and plate spacing
acceptable (lowest cost).

23. Finalise design: draw up the plate specification and sketch the layout.
Flow parameters:

• Feed = 152.798 k mole/hr , Xf = 0.938

• Distillate = 144.7 k mole/hr , Xd = 0.99

• Residue = 8.0931 k mole/hr , Xw = 0.177

• Column pressure = 2.08 atm

• Feed is at its boiling point. Hence q line is vertical.

Aspen Simulation Biodiesel Plant Page 29
From the graph: intercept of enriching section operating line for minimum reflux is obtained
from the graph, is given by:
xD / (Rm+1) = 0.946

Rm+1= xD/ 0.946 = 0.99/ 0.946

Rm = 1.046
Let R = 1.5×Rm ; Therefore, R= 1.5×1.046 = 1.569

• Number of Ideal trays = 12(excluding the reboiler).

• Number of Ideal trays in Enriching Section = 4

• Number of Ideal trays in Stripping Section = 8

Design of enriching section:

Tray spacing (ts) :

• let ts = 18 ” = 457 mm (range 0.15 – 1.0 m)

hole diameter (dh) :

• let dh = 5 mm (range 2.5 to 12 mm)

Hole pitch (lp) :

• let lp = 3 * dh (range 2.5 to 4.0 times dh)

i.e., lp = 3 * 5 = 15 mm

Tray thickness (tT ) :

• (tT ) = 0.6 * (dh )= 3 mm (range 0.4 to 0.7 times dh )

Ratio of hole to perforated area (Ah / Ap ) :

• (Ah/Ap) = ½ (π/4×dh2)/ [(√3/4) ×lp2]

= 0.1

Plate diameter (Dc):

• The plate diameter is calculated based on entrainment flooding considerations

• L/G {ρg/ρl}0.5 = 0.004 ---------- (maximum value)

Aspen Simulation Biodiesel Plant Page 30

(From fig. 18.10 p-18-7 Perry hand book 6th edition)

• L/G {ρg/ρl}0.5 = 0.004 and for a tray spacing of 500 mm.

• From the flooding curve………….Flooding parameter,
Csb, flood = 0.29 ft/s

• Unf = Csb, flood × (σ / 20) 0.2 [(ρl - ρg) / ρg]0.5

(From eqn. 18.2, page 18.6, 6th edition Perry hand book) where,
Unf= gas velocity through the net area at flood, m/s (ft/s) Csb, flood = capacity
parameter, m/s

σ = liquid surface tension, mN/m (dyne/cm.) ρl

= liquid density, kg/m3 (lb/ft3) ρg = gas density,
kg/m3 (lb/ft3)

Unf = 1.325 m/

Actual velocity, Un= 0.8×Unf

Un = 1.06 m/s
Volumetric flow rate of Vapour at the bottom of the Enriching Section
qo = 0.554 m3/s
Net area available for gas flow (An):
Net area = (Column cross sectional area) - (Down comer area.)
An = Ac - Ad
Net Active area,

An = qo/ Un = 0.554/ 1.06 = 0.522m2

Let Lw / Dc = 0.77 (range of 0.6 to 0.85 times Dc)

Where, Lw = weir length, m
Dc= Column diameter, m
Now,

θc = 2×sin-1(Lw / Dc) = 2×sin-1 (0.77) = 100.70

Ac = (π/4) * Dc2 = 0.785 * Dc2 m2

Ad = [(π/4) × Dc2 × (θc/3600)] - [(Lw/2) × (Dc/2) ×cos (θc/2)] Therefore DC = 0.87 m.

Aspen Simulation Biodiesel Plant Page 31

Perforated plate area (Ap) :

Ap = Ac - 2Ad

= 0.4496 m2

Acz = 2 * Lw * (thickness of distribution)

Area of calming zone, m2 (5 to 20% of AC)

Awz = 2*{(π/4)*Dc2* (θc / 360˚) – (π/4) * (Dc – 30 * 10-3)2 * (θc/360˚) }

Area of waste periphery,m2(range 2 tp 5 % of Ac)

AP= Ac -2Ad - Acz - Awz

Ap = 0.387 m2

Total hole area (Ah) :

Ah / Ap = 0.1

Ah = 0.1 * Ap

Ah = 0.0387 m2

Now we know that , Ah= nh × (π/4) * dh2

nt = number of holes = 1971 Weir height (hw) : let hw
= 50 mm

Weeping check:

• Head loss through dry hole

• Head loss due to bubble formation
• Height of liquid crest over weir

• Down comer flooding

• Head loss over down comer apron
Head loss through dry hole : hd = head loss across the dry hole

= k1 + k2 (ρg/ρl) Uh2
Where,
Uh is gas velocity through hole area

K1 and K2 are constants

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From sieve plates,
K1 = 0 and

K2 = 50.8/cv2

Where cv is discharge coefficient

(Ah/Aa) = 0.086 and ratio of tray thickness to hole diameter tT/dh = 0.60

For above values of (Ah/Aa) and tT/dh ,( from fig. edition 18.14, page 18.9 6th Perry)
We get
Cv(discharge coefficient) = 0.74 And
hence, k2 = 50.8 / 0.742 = 92.77

Volumetric flow rate of Vapour at the top of the Enriching Section

qt = 0.5514 m3/s -------- (minimum at top) Volumetric flow rate of Vapour at the bottom of
the Enriching Section qo = 0.554 m3/s. ---- (maximum at bottom) Velocity through the hole
area (Uh):
Velocity through the hole area at the top =
Uh, top = qt /Ah = 0.5514/0.0387= 14.25 m/s
Velocity through the hole area at the bottom= Uh, bottom = qo /Ah
= 14.31 m/s

hd, top = k2 [ρg/ρl] (Uh,top)2

= 92.77× (3.4376/784.69) * 14.252

= 82.526mm clear liquid . -------- (minimum at top)

hd, bottom = k2 [ρg/ρl] (Uh, bottom)2

= 92.77×(3.425/784.50) ×14.312
= 82.94 mm clear liquid ----- (maximum at bottom)

Head loss due to bubble formation : hσ = 409 [ σ / ( ρL * dh) ]

Where σ =surface tension (mN/m) dh

=Hole diameter, mm hσ = 409

Aspen Simulation Biodiesel Plant Page 33

[ 19.325 ( 784.69 x 5)] hσ = 2.014 mm
clear liquid Height of liquid crest over
weir : how = 664Fw
[(q/Lw)2/3]

q = liquid flow rate at top = 0.009 m3/min

Fw= correction factor = 1.03 Lw= weir length = 0.67m how= 2.520 mm clear liquid hd +
hσ = 82.526 + 2.014 = 84.54 mm ----------design value hd + how = 50 + 2.52 = 52.52 mm
since the design value is greater the minimum value, there is no problem of weeping.
Down comer flooding :

hds = hw + how + hhg /2 -------(eqn 18.10, page 18.10, 6th edition perry)
Where hw = weir height
hds = static slot seal how = height of crest over weir, equivalent clear liquid,
mm hhg = hydraulic gradient across the plate, height of equivalent clear liquid

hds = 52.77 mm
qHead loss over down comer apron :

hda = 165.2 {q/ Ada}2 Take clearance, C = 0.5” h ap = hds -

C = 52.77 – 25.4 = 27.37 mm

Ada = Lw x hap= 0.0183 m2 hda =

165.2[1.6061 * 10-4/ 0.0183] 2

= 0.0127 mm
ht = hd + hl` = 82.94+31.662 = 114.602 mm

Hdc (height of down comer) = ht+ hw + how + hda + hhg

=114.602 + 50 + 2.52 + 0.0132 + 0.0127
= 167.148 mm

h`dc = hdc / φ , where φ is the froth density.

= 167.148/ 0.5 = 334.29 mm which is less then the tray spacing , ts = 457 mm

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Summary of the distillation column

Enriching section Stripping section

T r a y s p a c i n g 4 5 7 m m 4 5 7 m m

Column diameter 0 . 8 7 m 0 . 9 4 m

W e i r l e n g t h 0 . 6 7 m 0 . 7 2 4 m

W e i r h e i g h t 5 0 m m 5 0 m m

H o l e d i a m e t e r 5 m m 5 m m

H o l e p i t c h 1 5 m m 1 5 m m

Tray thickness 3 m m 3 m m

Number of holes 1 9 7 1 2 3 0 8

F l o o d i n g % 8 0 8 0

COST ESTIMATION

An acceptance plant design must present a process that is capable of operating of

operating conditions which will yield a profit. Since net profit equal to income all expenses,it
is essential that a design engineer be aware of many different types of cost involved in
manufacturing process. Capital must be allocated for different plant expenses, such as those
for raw materials, labour and equipment . beside 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 inter plant communication .

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A capital investment is required for any industrial process and determination of the
necessary. Investment is an important part of the plant design . The total investment for any
process consists of the fixed capital investment for physical equipment and fecilities in the
plant plus working capital which must be available to pay salaries keep raw materials and
products on hand and handle other special items requiring direct cash out lay. Thus in an
analysis of costs and general expenses including income tax must be taken into consideration.
Cost estimation in industrial process is made for a number of reasons such as

• To enable feasible studies to be carried out

• To enable selection from alternative sources of environments
• To assist in selection from alternative design
• To provide information for planning the appropriate of capital.
• To enable the contracts to tenders for the new project.
The first in the preparation of a cost estimate both the capital investment and for
manufacturing or operating cost is to prepare a process flow sheet showing all major
items of the equipment including the flow lines and instrumentation. Heat and
material balances have to be compared so that the temperature and pressure and
composition of stream will be known. The next step is to calculate the size and
geometry of the equipment and to specify the material of the construction. Then a
preliminary cost estimation is made for the capital investment based on the
a.)The purchased cost of all equipment as shown in the flow sheet
b.)The manufacturing cost of the product from the material and energy balances
c.)The cost of raw materials , utilities, labor and depreciation.

1.) PURCHASED EQUIPMENT COST (PEC)

E q u ip men t Cost per unit(crores) N u m b e r o f u n i t s Total cost

R e a c t o r 2 . 1 5 1 2 . 1 5

M i x e r 0 . 2 2 1 2 0 . 4 4 2

Aspen Simulation Biodiesel Plant Page 36

Heat exchanger 1 . 2 9 1 1 . 2 9

P u m p 0 . 5 1 6 1 0 . 5 1 6

Distillation column 4 . 3 2 8 . 6

D e c a n t e r 0 . 6 4 5 1 0 . 6 4 5

T o t a l 8 1 3 . 6 4 3

2.) INSTALLATION COST INCLUDING INSULATION AND PAINTLNG::

10-15%OF PEC

Consider installation cost =15%PEC

=0.15*(13.643) =1.98 Cr.

3.) INSTRUMENTATION AND CONTROLLS INSTALLED:

50-70%PEC

Consider instrumentation cost=60% PEC=0.6*PEC=7.92 Cr.

4.) PIPING INSTALLED:

25-50% OF PEC

Assume 45%.

Piping cost= (0.45)*PEC=5.94 Cr.

5.) INSTALLATION COST:

10-40% OF PEC

Assume 15%

Electrical cost=15% of PEC=1.98 Cr.

Aspen Simulation Biodiesel Plant Page 37

6.) BUILDINGS PROCESS AND AUXILLARY:

10-70% of PEC

Assume 45%.

Considerable process and auxiliary cost=0.45*PEC=5.94 Cr.

7.) SERVICE FECILITIES:

30-80% OF PEC

Assume 55%

Service facilitate cost=(0.55)*PEC=7.26 Cr.

8.) LAND:

20% OF PEC

Land cost = (0.2*PEC) =2.64Crores.

9.) YARD IMPROVEMENT:

10-20% OF PEC

Assume 12%.

Yard cost=1.58 Cr.

10.) TECHNOLOGY AND ENGINEERING FIELD:

20% OF PEC

Cost =2.64 Cr.

Total direct cost=51.08 Cr.

INDIRECT COST

A.)ENGINEERING AND SUPERVISION:

15-35 OF DC (direct cost)

Assume 25%

Cost = (0.5*DC) =12.77 Cr.

Aspen Simulation Biodiesel Plant Page 38
B.)CONSTRUCTION EXPENSES AND CONTRACTORS FEE (CEC):

34% OF DC

CEC=O.34*DC=17.36 Cr.

C.)CONTINGENCY:

8-20% OF DC

Assume 15%.

Contingency cost= (0.15*DC) =7.66 Cr.

Total indirect cost=37.80 Cr.

FIXED CAPITAL INVESTMENT (FCI)

FCI=DC+IDC

=51.08+37.80

=88.89 Cr.

WORKING CAPITAL INVESTMENT (WCI)

10-20% of FCI

Assume 15%

WCI=13.33 Cr.

TOTAL CAPITAL INVESTMENT (TCI)

TCI=WCI+FCI=13.33+88.89 = 102.22 Cr.

ESTIMATION OF TOTAL PRODUCT COST

Total product cost=Manufacturing cost + General expenses

Manufacturing cost=Fixed charges + direct production cost +Plant overhead cost.

Aspen Simulation Biodiesel Plant Page 39

1.) FIXED CHARGES

A.)DEPRICIATION

10% OF FCI

Depreciation =8.88 Cr.

B.)LOCAL TAXES

3-4% 0F FCI

Local taxes=0.03*FCI=2.67 Cr.

C.)INSURANCE
1% OF FCI

INSURANCE=0.888 Cr.

Total fixed charges=12.44 Cr.

But Fixed charges=15% of TPC.

TPC=82.96 Cr.

2) DIRECT PRODUCT COST:

A.)RAW MATERIALS

10-40% of TPC

Raw material cost=24.88 Cr.

B.)OPERATING LABOUR

10-20 % OF TPC

Assume 15%

OLC=12.44 Cr.

C.)DIRECT SUPERVISORY AND CLINICAL LABOUR (DS&CL)::

DS&CL=20% OF OPERATING LABOUR=2.488 Cr

Aspen Simulation Biodiesel Plant Page 40

D.)UTILITIES

10-20% OF TPC

Assume 15%.

Utilities cost=12.44 Cr.

E.)MAINTENANCE AND REPAIRS

2-10% OF FCI

Assume 6%.

Cost =5.33 Cr.

F.)OPERATING SUPPLIES

15% of Maintenance cost.

Cost=0.80 Cr.

G.)LABOURATORY CHARGES

10-20% of operating labor cost.

Assume 15%.

Cost=1.86 Cr.

H.)PATENT &ROYALTIES

2-6% OF TPC

Assume 4%.

COST=3.32 Cr.

Total direct production cost= 63.54Crores.

PLANT OVER HEAD COST

50-70% of Operating labor, supervisory, maintenance

Assume 60%.

Aspen Simulation Biodiesel Plant Page 41

COST=12.16 Cr.

TOTAL MANUFACTURING COST=FC+DPC+POC=88.19 Cr.

GENERAL EXPENSES

A.)Administration cost

COST= 25%of OL =3.11Cr.

B.)Distribution and marketing cost

DMC=2-20% OF TDPC= 11.76 Cr.

C.)Research and development cost

3% OF TDPC

RDC=1.90Cr.

General expenses=ACC+DMC+RDC= 16.54 Cr.

TOTAL PRODUCTION COST=MC+GE=104.97 Cr.

GROSSEARNINGS/INCOME & RATE OF RETURN

Number of operating days in a year =330 days.

Cost of Biodiesel = Rs 42.47 per Kg.

Total annual sales=182.35 Cr.

Gross profit= 182.35-104.97=77.37 Cr.

Assume tax to be 35%

Net profit=Gross profit*(1-tax) = 27.08 Cr.

Rate of return=Net profit / (Total sales)*100=14.85%.

Pay out period=TCI / (NET PROFIT+DEPRICIATION) = 2.84 Years.

Break even analysis:

Total variable cost = TDC+PDC+GE
= 78.09

Aspen Simulation Biodiesel Plant Page 42

At the breakeven point FC+TVC = Net sales
Total capacity for an year = 1000 tons per year

PLANT LOCATION AND LAYOUT

The success of an industrial venture greatly depends on geographical location of the plant.
Enough care must be exercised in selecting the plant site and different factors must be
considered before finalizing the plant location. The plant should be located where the
minimum cost of production and distribution can be obtained, also keeping in view other
factors, such as room for expansion, safe living conditions for plant operating people and the
surrounding community, which is also important. Consciences regarding plant location
should be obtained before a design project reaches detailed estimate stage and firm location
should be established upon completion of detailed design.

The choice of final site should be based on complete survey advantages and disadvantages of
various geographical areas and, ultimately, on the advantages and disadvantages of available
real estate.

The source of raw material is one of the most important factors influencing the location of
the plant site because location near the raw materials source permits considerable reduction in
transportation and storage charges. Proximity to major markets is one important consideration
in selection of plant site. It should be noted that markets are needed for by-products as well as
for major final products. Power and fuel can be combined as another major factor in the
choice of a plant site as their requirements are high in most of the industrial plants. A location
near a source of fuel supply or large hydroelectric installations may be essential for economic
operations.

The plant site should have access to all types of transportation; certainly two types should be
available. The proximity to rail road centers and possibility of canal, river, lake or oceans
transport must be considered. The kind and amount of products and raw materials determine
the most suitable type of transportation facilities. Attention should be paid to local freight rates
and existing road lines.

Aspen Simulation Biodiesel Plant Page 43

Climate is a factor that should be examined when selecting a plant site. Improper selection
can have serious effect on the economic operation of a plant. The process industries use large
quantities of water for cooling, washing, steam generation and as a raw material. The plant
therefore must be located where a dependable supply of water is available. Thetemperature,
mineral content silt or sand content, bacteriological content and cost for supply and
purification treatment must also be considered while choosing the water supply. The site
selected for a plant should have adequate capacity and facilities for waste water disposal.

The permissible tolerance levels for various methods of waste disposal should be consider
carefully and potential requirements for additional waste treatment facilities should be
consider, even though a given area has minimal restrictions on pollution.

Type and supply of skilled and unskilled work force available in the vicinity of proposed
plant should be examined. Similarity state and local tax rates on property income,
unemployed insurance, local regulations on zoning, building codes, nuisance aspects and
transportation facilities have a major influence on the final choice of plant site.

Considering all the above factors and keeping in view the latest development trends, storage
facilities for raw materials and intermediate and finished products may be located, in isolated
areas or in adjoining areas. The plant can be located near any refinery such as MRPL, IOCL,
OR IPCL. As water needed in large quantity, the site near river will be quite feasible as water
can be obtained from it.

Plant layout involves the layout of process units in a plant and the equipment within these
process units. The layout can play an important parting determining construction and
manufacturing costs and thus be planned carefully with the attention being gives to future
problems that may arise. Plant layout means the disposition of the various equipment’s,
material and man power etc., andservices of the plant within the area of the site selected
previously. The plant layout begins with the design of the factory building and goes up to the
location and movement of the work table. All the facilities like equipment’s, raw materials,
machinery, tools, fixtures workers etc., are given a proper place. Rational design must include
arrangement of processing areas, storage areas and handling areas in efficient co-ordination
and with regards to such factors as

1. New site development or addition to a previously developed site.

Aspen Simulation Biodiesel Plant Page 44

2. Future expansion.

3. Economic distribution of services- water, process steams, power and gas.

4. Weather condition.

5. Safety consideration- possible hazards of fire, explosion and fumes.

6. Building code requirements.

7. Waste disposal problems.

8. Sensible use of floor and elevation space.

Principles of plant layout:

a. Integration:

It means the integration of production Centre facilities like workers, machinery, raw materials
etc., in a logical and balanced manner.

b. Minimum movements and material handling:

A few sound principals of plant layout have been brief as under, they are the principles
number of movements of workers and materials should be minimized. It is better to transport
materials in optimum bulk rather than in small amounts.

c. Smooth and continuous flow:

Bottle necks, congestion points and back tracking should be removed by proper line
balancing techniques.

d. Cubic space utilization:

Besides using the floor space of the room, the ceiling height is also to be utilized, so that
more materials can be accommodated in the same room.
Overhead material handling equipments save a lot of valuable floor space.

e. Safe and improved environment:

Aspen Simulation Biodiesel Plant Page 45

Working places-safe, well ventilated and free from dust, noise, fumes, odours and other
hazardous conditions decidedly increases the operating efficiency of the workers and improve
their moral. All this leads to satisfaction amongst the workers and thus better employer
employee relations.

f. Flexibility:

In automotive and other industries where models of products change after some time, it is
better to permit all possible flexibility in the layout. The machinery is arranged in such a way
that charges of the production process can be achieved at the least cost of disturbance.

g. Storage facilities and raw materials:

Intermediates and finished products may be located in isolated areas or in adjoining areas.
Hazardous materials stored in the large quantities should be isolated. Arranging storage of
materials so as to facilitate or simplify handling is also a point to be considered in design.

h. Economy of floor space:

Consistent with good housekeeping in the plant with proper considerations given to line of
flow of materials, access to materials, space to permit working on parts of equipment that
needed frequent servicing and safety and comfort of the operations. It is fundamental in
chemical engineering industries that the buildings should be around the process instead of
process being made to fit in buildings of conventional design of a new building to meet the
requirements of the process is more scientific.

i. Labour supply:

Skilled and unskilled labour is obtained in Indian states. The villagers near the sites can
accommodate for enough of unskilled labour and all the engineering graduates of colleges
can form the skilled labour.

j. Market:

This is one of the major declining factors of plant location and in this respect the plant should
be near a big city, which should be a major trade centre so that a lot of money can be saved
on transportation charges and final product will have a heavy demand.

Aspen Simulation Biodiesel Plant Page 46

Aspen Simulation Biodiesel Plant Page 47
ENGINEERING PROBLEMS AND SAFETY CONSIDERATIONS

ENGINEERING PROBLEMS:

Engineering problems in hydrolysis of organic compounds is that organic compounds, being

stable compounds, require relatively high reaction temperatures. However, once reaction has
started, the intermediate products are much less stable and the reaction tends to drive
temperatures out of control.

Direct oxidation of organic compounds is carried out commercially by vapour phase and
liquid phase processes, the liquid phase processes are practiced at somewhat lower
temperatures and therefore sophisticated systems.

SAFETY CONSIDERATIONS:

There is every incentive and a real necessity foe including a survey of safety and fire hazards
in a study of chemical engineering processes. Some of the important safety considerations in
the chemical industries where toxic substances are manufactured, handled or used are
summarized here. Suitable services should be installed where ever possible to give warning in
case of liberation quantities of these substances. Every operation or process involving use of
irritating and the packing of the product should be effected by mechanical means is apparatus
provided with adequate enclosures and dust collecting systems in order to curtail atmospheric
contamination. Any spillage of irritating or toxic dry compounds should be removed as
quickly as possible, preferably by vacuum apparatus.

All personnel exposed to toxic substances should be provided overalls or working clothing
and also a time allowance of not less than 10 minutes at the expense of the employer for the
use of baths at the end of days’ work.

One or more aid tips or cabinets, containing sufficient and suitable first aid dressing
and other equipment should be provided and maintained in easily available locations for
immediate temporary treatment in case of accident or sudden illness.

In addition to chemical hazards, mechanical hazards, electrical hazards are also to be dealt
with by recognizing and incorporating with minimum safe practices prescribed by nationally

Aspen Simulation Biodiesel Plant Page 48

recognized protection associations, engineering authorities and government bodies. Fire
prevention and control, good ventilation systems are also indubitably important aspects to be
considered for the safe and successful operation of chemical process industries.

Measures to prevent and control circumstances which produce fatigue, such as excessive
noise, inadequate ventilation, poor lighting, excessive heat and humidity, to the workers are
to be taken. Sanitation in the plant should also be taken into consideration. Safety must be
considered when dealing with disposal of wastes as effecting persons outside the jurisdiction
of the plants. All the personnel should be thoroughly informed of the hazards connected with
their duties and the measures to be taken to protect themselves there from.

The management should take special responsibility of those who have placed their health,
welfare and livelihood in their hands, to invite a sense of security, as safety hazards and
potential deterrents to attainment of optimum technical efficiencies and product quality. No
matter highly satisfactory a plant design may be from the technical and economic view point,
disregard of safety, air pollutions and disposal problems will nullify an otherwise sound
engineering plant design.

POLLUTION CONTROL AND SAFETY

The effluent from Nicotinamide plant consists of mainly blow downs of condensers, cooler
and condensates from distillation column. These may contain negligible amount of
Nicotinamide.

STORAGE & HANDLING

Keep in a tightly closed container. Store in a cool, dry ventilated area from sources of
ignition. Protect against physical damage. Store separately from source of heat or ignition.
Protect against physical damage. Store separately from reactive or combustible materials and
out of direct sun light. Avoid dust formation and control ignition sources. Employ grounding
venting and explosion relief provision in accord with accepted engineering practices in any
process capable of generating dust and or static electricity. Empty only in to inert or non-
flammable atmosphere. Emptying contents into a non inert atmosphere where flammable
vapours may be present could cause flash fire or explosion due to electrostatic discharge. All
workers should be properly trained on its hazards and the proper protective measure required.

Aspen Simulation Biodiesel Plant Page 49

This training should also include emergency actions. All product operations should be
enclosure to eliminate any potential exposure routes. Containers of this material may be
hazardous when empty since they retrain product residue observe all warnings and precaution
listed for the product.

EXPOSURE CONTROL/PERSONAL PRODUCTION

Airborne exposure limits

OSHA Permissible Exposure limit (PEL): 5ppm (TWA) (skin)

ACGIH Threshold limit value (TLV) :5ppm (TWA) (skin)

VENTILATION SYSTEM:

A system of local is generally preferred because it can control the emission of the
contaminant at its source, preventing dispersion of it into the general work area. Please refer
to the ACGIH document, Industrial ventilation manual of recommended practices most recent
edition for details.

PERSONAL RESPIRATORS (NIOSH APPROVED):

If the exposure limit is exceeded a full face piece respirator with organic vapour cartridge and
dust/mist filter may be worn up to 50 times the exposure limit or the maximum use
concentration specified by the appropriate regulatory agency or respirator supplier whichever
is lowest. For emergencies or instance where the exposure levels are not known use a full
face piece positive pressure air supplied respirator.

SKIN PROTECTION:

Wear impervious protective clothing including boots, gloves, lab coat, apron or coveralls to
prevent skin contact. Butyl rubber and neoprene are suitable materials for personal protective
equipment.

EYE PROTECTION:

Use chemical safety goggles and or full face shield where dusting or splashing of solution is
possible. Maintain eye wash fountain and quick-drench facilities in work area.

Aspen Simulation Biodiesel Plant Page 50

BIBLIOGRAPHY:
1) Biodiesel production,Transesterification of Vegetable Oil and Methanol ,David
Houghton, Desirée LeBlanc, Michael Thiessen.
2) Dhar, B., & Kirtania, K. (2009). Excess Methanol Recovery in Biodiesel Production
Process Using a Distillation Column: A Simulation Study. Chemical Engineering
Research Bulletin, V.13 No.2.
3) Hillion, G., Delfort, B., le Pennec, D., Bournay, L., & Chodorge, J.-A. (2003).
Biodiesel Production By A Continuous Process Using a Heterogenous Catalyst.
France: Institut Français du Pétrole.
4) Leazer, J. (2013). Transforming Paper Mill Pollution into Commercial Resource.
United States Environmental Protection Agency: Science Matters Newsletter.
5) MacLeod, R. (2009). Waste Vegetable Oil Survey Report. Sault Ste. Marie: Science
Enterprise Algoma.
6) Muea ﾐﾏ as, C., P ヴ ase ヴ tsit, K., & To ﾐ gu ヴ ai, C. ふヲヰヱヰぶ. T ヴ a ﾐ seste
ヴ

ifiIatio ﾐ of T ヴ iolei ﾐ ┘ith Metha ﾐ ol i ﾐ Reactive Distillation Column: Simulation

Studies. International Journal of Chemical Reactor Engineering,V. 8-A141.
7) Noor Azian Morad, A.A. Mustafa Kamal, F. Panau, & T.W. Yew. (2000). Liquid
Specific Heat Capacity Estimation for Fatty Acids,Triacylglycerols, and Vegetable
Oils. Journal of the American Oil Chemists' Society, V.77, No.9.
8) Sup Yoon, E., & Kim, I. (2011). Process Modeling Using Aspen Plus (Flowsheet
Convergence). Seoul: Seoul National University.
9) Thomas, A. (2002). Fats and Fatty Oils. In Ullmann's Encyclopedia of Industrial Chemistry.
Wiley-VCH.

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