(DEEMED UNIVERSITY)
PATIALA, PUNJAB
Respected sir,
Sincerely,
VARUN AGGARWAL
Ist year T.I.E.T student
Team members:
VARUN AGGARWAL
MISHIKA SINGLA
RAHUL KUMAR
TANSY JINDAL
TABLE OF CONTENTS
ACKNOWLEDGEMENTS……………………………………… (i)
SUMMARY……………………………………………………… (ii)
1.0 INTRODUCTION…………………………………………… 1
1.1 Problem overview…………………………………… 1
1.2 Report objectives…………………………………… 1
6.0 CONCLUSIONS…………………………………………… 10
8.0 REFERENCES…………………………………………….. 11
I would also like to thank Dr. Maneek Kumar and Dr. Ajay Batish,
faculty members in the institute. Their guidance and advice was
invaluable, and was used frequently throughout the course of
project.
i
SUMMARY
This report will channelise the various possible areas suitable for
cultivation of Jatropha plant along with its justification. It will
outline the processes involved in extracting oil from plant which acts
as raw material for fabrication of biodiesel, also it will show detailed
process followed in making a biodiesel processor. It will justify
every decision made using analytical data, calculations and
professional opinions.
ii
1.0 INTRODUCTION
1
2.0 BACKGROUND
There are more than 100 tree species which bear seeds rich in oil having
excellent properties as a fuel and which can be processed into a diesel
substitute. Of these some promising tree species have been evaluated and
it has been found that Pongamia
Pinnata and Jatropha curcas are most
suitable. However, the advantage is
clearly in favour of Jatropha curcas
due to the following reasons. Fig. 2(a)
shows the different areas under
Jatropha cultivation in India.
• It can be grown in areas of low
rainfall (500 mm per year) and
in problem soils. In high
rainfall and irrigated areas too
it can be grown with much
higher yields. Therefore, it can
Fig. 2(a) Areas under
be grown in most parts of the Jatropha cultivation
country. It can be grown in
desert areas, with the help of
drip irrigation.
• Oil yielding per hectare is among the highest of tree borne oil
seeds
• Animals do not graze Jatropha.
• Being rich in nitrogen, the seed cake is an excellent source of plant
nutrients.
• Various parts of plant are of medicinal value, its bark contains
tannin, the flowers attract bees and hence plant has honey
production potential.
• The plant is undemanding in soil type and does not require tillage.
Diesel engines require, starting from Vegetable oil Diesel and now Bio
diesel, as fuel. There are numerous benefits of using biodiesel as
compared to petroleum diesel. As of
now biodiesel is the only alternative
fuel, which requires no alterations to,
and can be run in, an existing diesel
engine. Biodiesel in its pure form, or
mixed in any proportion with
petroleum diesel has no negative
affects on the performance of a
diesel engine. Biodiesel is much safer
than petroleum diesel as it is 10
times less toxic than table salt, and
has a flash point (point at which it
ignites) of 125°C as compared to a
Fig. 2(b) Reduction in emissions
flash point of 55°C for petroleum
using biodiesel as fuel
2
diesel. Biodiesel can also have a very positive affect on the local economy.
It reduces the dependency on foreign oil, and benefits local farmers,
businesses and the national economy.
One of the major benefits of biodiesel is the reduction is harmful
emissions. Fig. 2(b) shows the reduction in emissions as biodiesel is
mixed with petroleum diesel in different ratios. All of these reductions in
emissions reduce environmental and human hazards such as global
warming, health affects, and smog. One negative affect of biodiesel is that
it can cause a slight increase in Nitrous Oxide emissions as compared to
Petroleum diesel [1].
The seeds and the leaves are the oil-bearing parts of the plant. The oil is
extracted from them by any of the following
methods:
• The Sayari expeller:
As shown in the plate (i) showing how we
get oil from the seeds of Jatropha plant.
Plate (i)
3
Essentially this process is just thinning the oil so it can be used in an
existing diesel engine.
¾ Step 3 – Titration:
¾ Step 7 – Allow to settle for eight hours. This will let the glycerin
separate from the mixture and settle to the bottom.
4
3.0 PROCESSOR DESIGN
Fig. 3(a) The Concept Biodiesel Processor Fig 3(b) The Fabricated Bio-diesel
Processor
5
The frame is to be made and all
supports are to be made out of
angle iron, rectangular tubing or
round pipe. 1” angle iron is not
strong enough and 2” angle iron is
not in stock. Round pipe is more
difficult to weld a base sheet onto
so 1” square tubing will be used for
the platform and 1” x 2”
rectangular tubing will be used for
Fig 3.2(b) Different
the tank supports. angle iron rods
Fig 3.2(a) Comparison of
GI and MS
3.3 COMPONENTS
(ii) Air compressor- It is used for bubble washing of biodiesel. The air
bubble allows a sort of indirect agitation of two fluids-they pick up a tiny
amount of water and gently carry it through the biodiesel, picking up
soaps and other contaminants.
This method of bubble washing is efficient and cheaper.
6
3.3.2 Selection
(i) Pump Selection
The main criteria when selecting a pump is the
capacity. When titrating the 150L batch the
liquid needs to be re-circulated reasonable
quickly so the user is not forced to wait for an
extended period of time while the batch
titrates. In order to mix thoroughly the batch
should be re-circulated a few times before
taking the final titration reading. This should
not take any longer than 15 minutes. The
calculation below shows the rough pump
capacity required for this processor.
Fig. 3.3(c) pump used
Pump capacity (L/hr) = 450L/0.25hr
= 1800L/hr
The pump capacity should be around 1800L/hr. A pump with a capacity of
much less than this will result in a long wait time for thorough mixing, and
a pump much larger than this will result in a cost more than allowed for
by the budget.
(ii) Heater Selection - In order to produce the desired environment of
550C, the heater is used. The oil and the methanol is thoroughly mixed
and heated in the cylindrical processor. The thermostat in the heater
serves our purpose of the required temperature.
We needed a heater that would heat 150L of vegetable oil in a reasonable
amount of time. To estimate the size of the heater needed some
calculations were performed: Assuming the density of the vegetable oil to
be 0.91kg/L [3], the mass of the oil in a 150L batch was calculated to be
136.5Kg. A reasonable amount of time to heat the oil was set as 15
minutes and the specific heat capacity of the oil was assumed to be 1.67
KJ/Kg [4]. A base temperature of 25°C was used and because the oil
needs to reach a temperature of 55°C ∆t was made to be 30°C.
E=mc∆t = 136.5Kg x 1.67KJ/Kg x 30°C = 6,838,655J
6,838,655 / 900seconds ≈7.5kW
Therefore the heater needed to be about 7.5kW.
7
3.4 USER INTERFACE
3.4.1 Safety
While working with the processor, care must be taken, as there could be
any sharp edge of the processor tank. Most dangerous part is while mixing
methoxide whose caustic dusk particles can make damage to lungs.
Methanol fumes are dangerous to the eyes, can cause blindness. There is
risk of spreading of methanol fumes during bubble or mist washing. Its
fumes are inflammable. Also there may be a risk of getting exposed to hot
fumes or electric currents. NaOH can also cause severe burns.
3.4.2 Maintenance
The unit was designed to be relatively maintenance free. If the paint
wears off after an extended period of time a touch up coat should be
applied to prevent rust. Also if the unit is expected to sit idle for an
extended period of time it should be completely drained. This is once
again to prevent rust. All of the electrical wiring was made easily
accessible in case any of the electrical components should fail. All parts of
the processor are easily accessible and the control panel handles the
electrical switching of all these parts, thus its maintenance is relaxed.
3.4.4 Aesthetics
With the knowledge that the biodiesel processor would be displayed in
an IIT competition in May, aesthetics were even more important than they
would otherwise be.
4.1 ASSEMBLY
8
Phase 2: Assembly of various components
After this, the rest of the components like the centrifugal pump, the heater,
the air-compressor, the pH meter etc. were chosen according to their
specifications and fitted at their appropriate places, like heater was placed
at the bottom of the conical flask.
Phase 3: Making of the control board:
The final step was to construct the control board that provides various
switches to control all the components. This was designed keeping in view
the user convenience.
5.0 COST
By the end of the project, the total cost of materials was Rs 35,880. The
list of materials and their costs can be seen in appendix B. It was
estimated that the amount of Labour required in fabricating the processor
by skilled workers would be 50hrs. Using the cost of Rs 100/hr [2] the
total labor cost was calculated to be Rs 5000. The total cost of the project
was then calculated to be Rs 40,880.
9
With the limited amount of time available it was not possible to make a
test batch of biodiesel, but the cost of making biodiesel was still
calculated. The cost of methanol in India was found to be Rs 32/L [5]. The
cost of Lye (sodium hydroxide) was found to be Rs 160/kg [6]. The
following calculation uses the two values listed above. It also assumes
that the vegetable oil can be obtained at no cost from a local restaurant
as used deep fryer oil, and that 20L of glycerin is drained following the
titration process.
Taking into consideration that we wont get 100% used vegetable oil, so
we will have to use mixture of these two. But whatever the situation is,
calculations clearly show that net cost is lesser than the present cost of
diesel.
6.0 CONCLUSIONS
Due to the tight schedule there was not enough time to make a test batch
of biodiesel. However, all of the individual components were tested and in
working order. When compared to purchasing petroleum diesel, making
biodiesel results in significant savings. Calculations show that the cost of
fabricating a biodiesel processor will be quickly offset by the savings
generated after making a few batches of biodiesel. Building a prototype
processor has also showed that there is much room for improvement in
both the design and fabrication processes. A slightly different design and
more time could result in a much more inexpensive processor.
7.0 RECOMMENDATIONS
If this same project were to be undertaken again there are numerous
things that should be done differently. Making two nearly concentric tanks
and a cone to fit on the bottom was much more difficult and time
consuming than planned for. It is recommended that the tank design be
changed to a rectangular prism shape with a four-sided pyramid instead of
10
the cone for the bottom. This design does use more material, but it would
save several hours during the fabrication process.
8.0 REFERENCES
[7] – The Tribune, Petrol, Diesel Prices Hiked by over Rs 2, Manoj Kumar,
11
APPENDIX A: – Biodiesel Making Process
12
APPENDIX B: List of materials
Pre batch (Chemicals):
• 150L of crude oil
• ~30L of Methanol (99+% pure)
• ~1Kg of Lye (96+% pure NaOH)
13
Appendix C
Description of Biodiesel:
14
Other Precautions: None
15