BIO DIESEL-WHY & HOW ?

School Of Bio-Medical Engineering and Research (Department of Biotechnology)

The Indian Petroleum Scenario

Consumption of petroleum products Import of crude & POL (2003-04) Production of crude Consumption of HSDO & LDO Consumption of motor gasoline (petrol)

-120 MMT - 90 MMT - 33 MMT - 45 MMT - 10 MMT

Oil Economy
Oil import constitutes a major part of our trade deficit and has an enormous impact on our economy and creation of new jobs We spent annually more than 150,000 crores on import of petroleum Some day we may be faced with an oil crisis that is not temporary; today oil field discovery and production is on the decline. Developing a strong market for bio diesel would have tremendous economic benefits Investments in biodiesel technology may ensure that we have transportation fuel options and we will not be so vulnerable

Bio Fuels

Oxygenated organic compounds from cellulosic biomass Bio ethanol, Biodiesel Others include: bio methanol, DME, ETBE, pyrolysis oils, Fischer-Tropsch fuels Can provide a market share of ~15%

Why Bio Fuels?

SECURITY OF SUPPLY SUSTAINABILITY REDUCTION OF GREEN HOUSE GAS EMISSIONS REGIONAL (RURAL) DEVELOPMENT SOCIAL STRUCTURE & AGRICULTURE

Bio Diesel
Made by chemically combining any natural oil or fat with an alcohol Most European Countries, North America and Canada have active Biodiesel programmers France currently the largest producer USA produced 30 million gallons in 2004.

VEGETABLE OILS AS FUELS

THE USE OF VEGETABLE OILS FOR ENGINE FUELS MAY SEEM INSIGNIFICANT TODAY. BUT SUCH OILS MAY BECOME IN COURSE OF TIME AS IMPORTANT AS PETROLEUM AND COAL TAR PRODUCTS OF THE PRESENT TIME
Rudolf Diesel at the Engg. Society of St. Louis, 1912

Environmental Issues
Burning fossil fuels increases atmospheric levels of carbon dioxide Fossil fuels are a finite resource

(Graph taken from USF Oceanography webpage)

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Raw Materials
Rapeseed, the major source (>80%) Sunflower oil (10%, Italy and Southern France) Soybean oil (USA) Palm oil (Malaysia) Linseed, olive oils (Spain) Cottonseed oil (Greece) Beef tallow (Ireland), lard, used frying oil (Austria), Jatropha (Nicaragua), Guang-Pi (China)

Bio diesel Production Basics

Three basic routes Base catalyzed transestrification Acid catalyzed transestrification Conversion of oil to fatty acids and then to Easter by acid catalysis

Bio Diesel - Manufacture

CH2-O-COR | CH-O-COR + 3ROH | CH2-O-CO-R KOH, rt, 6h 3RCOOR +

CH2-OH | CH-OH | CH2-OH

(100 kg) Oil

(10.55 kg) (.1 kg) Alcohol KOH

(100 kg) Bio Diesel

(10.55 kg) Glycerin

10 Liters Biodiesel Unit

Stirrer Water Cooled Condenser

Cooling Water

Reaction Vessel Heating Element

Development Cost : US $ 1300

Base Catalysed Transestrification

Most popular of all method >90% of all bio diesel by this method Low temperature ( 150o F) and pressure (20 PSI) High conversion (>98%) Minimum side reactions Direct conversion- No intermediate step Ordinary material of construction

Effect of Free Fatty Acid (FFA)

Soap formation Excessive utilization of alkali Loss of yield Slower reaction Incomplete conversion For best conversion FFA should be lower than 0.8%

Troubleshooting in high FFA containing oils

Formation of soap Reduction in catalyst efficiency Separation process is difficult Low yield of Easter (Bio diesel) Therefore, two stage method was used Esterification of FFA with mineral acid Tranesterification with lye

Bio diesel Process Flow Diagram

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DIESEL vs. BIODIESEL

Me Ester Density 150C, g/l Viscosity Cetane number 400C, mm2/s
4.3-4.5 64.3-70.0

Iodine value Lower heating value (MJ/kg)

52 37

Palm oil

872-877

Rapeseed oil

882

4.2

51-59.7

114

37.2

Soybean oil

880

4.0

45.7-56.0

131

37.1

Diesel fuel

830-840

1.2-3.5

51

42.7

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HEAT OF COMBUSTION
Petro-diesel Biodiesel (soybean) 130,500 BTU/gallon 128,000

Petro-diesel Biodiesel (Rapeseed)

18,400 BTU/lb 17,900 BTU/lb

Net fuel combustion efficiency is increased most noticed at low rpm and high engine load

POWER OUTPUT
Small difference in overall power output SRI Study (Cummins truck engine) 20% Blend Neat 98.5% relative to petro diesel 92%

Tennessee Study (Volvo marine engine, 110 HP) Neat biodiesel power output 2-7% lower At max throttle (3800 rpm), both fuels performed the same At the lowest engine speed (1855 rpm), at full throttle and output was 13% higher heavy load, power

FUEL CONSUMPTION
Biodiesel contains ~10% oxygen Consequently, slight increase in the apparent fuel consumption rate 2% for B20 blend; 14% for B100 (Cummins engine) Brake-specific fuel consumption figures Petro diesel 0.43 lb/HP-hr B20 0.44 B100 0.50

 Biodiesel generates 573.96 g/bhp-h compared to 548.02 g/bhp-h for petroleum diesel The overall life cycle emissions are 78.45% lower for biodiesel; direct result of carbon cycling by the soybean plants The higher CO2 levels result from more complete combustion

LIFE CYCLE EMISSIONS CO2

CARBON TRADING POTENTIAL

Reduction in GHG (CO2) 1 Ton bio-diesel avoids App. 3 ton CO2e Certified Emission reduction (CER) 1 ton of CO2e 1 CER @ US $ 5 75 p/ liter additional revenue

EFFECT ON ENGINE SEALS, GASKETS, HOSES

Bio diesel has strong solvent properties Natural rubber and soft plastics especially vulnerable Problem substantially reduced for the B20 blend The only hose and gasket material that is truly resistant to biodiesel is Viton

BIODIESEL vs. OTHER ALTERNATE FUELS

DIESEL CNG LNG METHANOL ETHANOL BIODIESEL

___________________________________________________________________________ Vehicle cost 10 5 5 5 5 10 Infrastructure 10 2 5 5 5 10 Safety 7 4 3 1 3 8 Operating range 10 5 10 10 10 10 Operating cost 10 5 7 5 5 7 Reliability 10 7 5 3 3 10 Customer acceptance 5 8 8 8 9 8 Funding assistance 1 10 2 0 2 2 Training cost 10 5 5 5 5 10 Fuel availability 10 10 5 5 5 6 Fuel quality 9 5 10 8 8 9 Fuel price stability 6 8 8 6 6 6 TOTAL 98 74
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Feed Stocks for India

Feed stocks used in different Countries

Feedstock Rape seed , Sunflower Soya bean Palm Oil Coconut Linseed & Olive oil Cotton Seed Oil Jatropha Curcas Oil Used Cooking Oil Beef Tallow Used frying Oil EU U.S.A. Malaysia Philippines Spain Greece Nicaragua Japan Ireland , USA Australia Countries

WHY JATROPHA THE SUITABLE CHOICE ?

Thrives on any type of soil Needs minimal inputs or management Has no insect pests Not browsed by cattle or sheep Can survive long periods of drought Propagation by seed/cutting is easy Rapid growth Yield from the 2nd year onwards Yield from established plantations 5 tonne per ha. 30% oil from seeds by expelling Seed meal excellent organic manure

Target Output per Hectare

Estimated Biodiesel production per Hectare = 3,000 litres/700Gal Potential yields of 12 tonnes per hectare and 55% oil Extraction are also attainable

2500 trees per hectare produces Seed 6.9 tonnes Seedcake 4.2 tonnes Vegetable Oil 2.7 tonnes Glycerol 0.27 tonnes

Anti-Erosive Properties

Reduces wind and water erosion of soil Improved absorption of water by soil

Properties of press cake as fertilizer

Quality seedling preparation

10 x 20 cm bag Germination -3 days 3-6 months old seedlings

VIEW OF JATROPHA PLANT NURSERY

Indian Biodiesel Program

Name of Biodiesel started making appearance at Indian Conferences, Workshops & Seminars in 1999 Report of the Committee on Development of Biofuel Planning Commission, GOI in 2003 Stage I Demonstration Project use Jatropha curcas on 400,000 ha (0.5 MMT BD) Nation-wide investment $ 300mn Stage II 11 mill ha (13 MMT biodiesel) for 20% blend. Demonstration project started with initial grant of $11mn for nursery raising rest is expected to be sanctioned late this year First 10,000 TPA plant in Hyderabad about to start production Garware100,000 TPA DMT plant modified for biodiesel production A 250,000 TPA plant is being setup in

CAN BIODIESEL WORK IN INDIA?

India with just 2.4% of global area supports more than 16% of the human population and 17% of the cattle population India is one of the largest importers of edible oil Where do we find the oil for biodiesel? A sustainable source of vegetable oil is to be found before we can think of biodiesel
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Jatropha (Jatropha curcas, Ratanjyot, wild castor) thrives on any type of soil Needs minimal inputs or management Has no insect pests, not browsed by cattle or sheep Can survive long periods of drought Propagation is easy Rapid growth; forms a thick live hedge after only 9 months of planting Yield from the 3rd year onwards and continues for 25-30 years Yield from established plantations in Brazil, 1.5 to 2.3 tons per hectare 25% oil from seeds by expelling; 30% by solvent extraction The meal after extraction an excellent organic manure (38% protein) According to the National Mission on Bio Fuels out of 197 million hectors,13.4 MH available for Jatropha plantation

JATROPHA THE ANSWER?

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BIODIESEL FROM JATROPHA

1 MILLION HECATRES OF WASTE LAND IS BROUGHT UNDER JATROPHA CULTIVATION
Can yield 0.8-1 million tons of oil For 66.9 MMT diesel (Projected 2011-12) 13 MMT bio diesel for 20% blend 11 MH land required 11 million jobs
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Initiatives taken by Govt

Planning commission Indian Railways Planted 7.5 million Jatropha plants on railway track Bureau of Industrial Standards (BIS) has given specification for pure bio-diesel (B100) MOP&NG Oil marketing companies to make available comprehensive industry guidelines Operation, Quality & Safety IOC R&D taken up extensive studies
MSP of Bio-diesel Rs.25/- per liter 20 centres designated for blending Committee formed Report

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Initiatives taken by State Govt.

Various State Govts have taken initiatives for Jatropha Plantation notably Uttranchal Constituted Uttranchal Bio-fuel Board to promote Bio-fuel in the state 2 lakh ha.Jatropha plantation is proposed on degraded community land through Van Panchayat Chhattisgarh Chhattisgarh Bio-fuel Development Authority setup on Jan.2005 for development of bio-fuel in the state Govt. fallow land being offered to private entrepreneur. Action initiated to allot 70000 ha Land on lease to private entrepreneur

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RESEARCH & DEVELOPMENT National Network on Jatropha

Objectives Selection of Superior planning material Standardization of Propagation techniquesMicro and Macro propagation. Standardizing agro- techniques Establishment of model plantation Tree improvement Detoxification of seed meal Development of pre-processing & processing equipments Imparting training to the farmers.
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Issues for Investors

Feed stock souring own /external source Long term contract Technology Appropriate for multi food stock Etraction of value added feed stock like phytochemical formulations during pre treatment Product quality Economic consumption of chemicals
Domestic Export

Glycerin quality & outlet Process plant size Transportation Infrastructure sharing

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Cost of Bio Diesel Production in India

(As per Planning Com Report)
Rate (Rs. Kg) Seed Cost of collection & oil extraction Less cake produced Trans- esterification cost * Less cost of glycerol produced Cost of Bio- Diesel per Kg Cost of Bio Diesel per liter ( SP. Gravity 0.85) 5.00 2.36 1.00 6.67 *40 to 60.00 Quantity(Kg) 3.28 1.05 2.23 1.00 0.095 Cost (Rs.) 16.40 2.48 -2.23 6.67 -*3.8 to 5.70 19.52-17.62 16.59-14.98

The price of glycerol is likely to be depressed with processing of such large quantities of oil and consequent production of glycerol. However , new applications are likely to be found 06 NRRaje Feb creating additional demand and stabilizing its price.

Issues of Seed / Oil Allocation

Investors perspective Legislated for seed / oil allocation Price Policy on contract farming Feasibility / project report Covering all aspects of farming including yield guarantees. Farmers perspective Seed quality/ certification No certification available for non-edible oil seeds Management practices for Jatropha cultivation Crop behavior Holding pattern 11 million hectares 1crore farmers assuming 3,000 / hectare loan 3,000 crore required by farmers

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Long Term Govt. Policies

Long term plan for Energy Encourage production & usage of bio fuels Standards notification Directive /policy on procurement distribution & allocation of seeds / oils Firm Selling Price Policy on Excise & Sales Tax Encouraging Policy Customs duty Waiver on non-edible oils import & machinery initially
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Conclusion
Obviously, energy problems are on the horizon Alternative fuels offer near term solutions Ethanol and biodiesel offer great environmental benefits and decent economic benefits Off-the-grid solutions are emerging
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Websites to visit
www.ethanol.org www.ethanoltoday.com www.biodiesel.org

Thanks For Attention

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