Development of Biodiesel Conversion Plant and Properties

Comparability with Mineral Diesel.

Project report submitted in partial fulfilment of the requirement for the degree
of
Bachelor of Technology
Under Supervision of
Er. J.N. Gangwar
By-

Vijay Kumar Patel

20103082

Satyanarayan

20103080

Satyendra Kumar Patel

20103056

Tarachand Kumar Maurya

20103069

Saurabh Kumar

20103054

Department of Mechanical Engineering,

Motilal Nehru National Institute of Technology,
Allahabad, UP - 211004.
( May, 2014 )
0

Certificate

This is to certify that the project entitled Development of Biodiesel Conversion Plant and
Properties Comparability with Mineral Diesel submitted by Vijay Kumar Patel
(20103082), Satyanarayan (20103080), Satyendra Kumar Patel (20103056), Tarachand
Kumar Maurya (20103069) and Saurabh Kumar (20103054) in partial fulfilment of the
requirement of the degree, Bachelor of Technology in Mechanical Engineering has been carried
out under my supervision and that this work has not been submitted elsewhere for a degree.

Date:

27/04/2014

Place:

Allahabad.

Signature of Supervisor
Er. J.N. Gangwar
Asst. Professor,
Department of Mechanical Engineering,
MNNIT Allahabad - 211004.

Undertaking

We hereby declare that the written submission presented in this report titled Development of
Biodiesel Conversion Plant and Properties Comparability with Mineral Diesel under
supervision of Er. J.N. Gangwar, represents our ideas in our own words and where others'

ideas or words have been included, we have adequately cited and referenced the original
sources. We also declare that we have adhered to all principles of academic honesty and
integrity and have not misrepresented or fabricated or falsified any idea/data/fact/source
in our submission.
We understand that any violation of the above will be cause for disciplinary action by
the institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.
Finally, we also declare that we have not submitted the same report anywhere else for the award
of a degree.

Date:

27/04/2014

Place:

Allahabad

Students:
1) Vijay Kumar Patel

20103082

2) Satyanarayan

20103080

3) Satyendra Kumar Patel

20103056

4) Tarachand Kumar Maurya

20103069

5) Saurabh Kumar

20103054

Acknowledgement

We are extremely grateful to our project guide Er. J.N. Gangwar, Assistant faculty of
Mechanical Engineering Department, for his guidance and encouragement, which has led us to
the completion of the project. Without his constant appraisal and continuous efforts, this task
would not has been possible in present form. He provided us all the necessary guidance,
technical support and moreover the moral support and motivation during whole course of
project.
We are also thankful and grateful from bottom of our hearts to our esteemed visiting faculties
Prof. S. K. Agrawal, Prof. R. K. Srivastava (HOD), Prof. H. S. Goyal, Prof. Ravi Prakash,
Dr. S. K. Poddar, Mrs. Vandana Agrawal, Dr. Rahul Dev, Er. Bireswar Paul and Er.
Manoj Kumar Gupta. Without their continuous support and valuable appraisals this project
would not have been possible in present form.
We are thankful to Dr. Samir Saraswati for his guidance and kindness. Without his support
our small lab would not have been so arranged.
We are also thankful to the Thermodynamics Lab (Mechanical Engineering department),
Chemistry Department and Environment and Ecology Lab (Civil Engineering department) for
providing us various equipment during production and properties testing. We are grateful to
our PhD scholars in Mechanical engineering department, Ecology department and Chemistry
department and our MTech counterpart for their valuable support.
Finally we also thank one and all who helped us directly or indirectly in carrying out this project
work.

Index

Certificate
Undertaking
Acknowledgement
1. Chapter 1
1.1. Abstract
1.2. Scope of project
1.3. Objective of project
2. Chapter 2
2.1. Introduction
2.2. Biodiesel
2.3. Physical Characteristics of biodiesel
2.4. Physiochemical properties of methyl esters
2.5. Advantages and limitations of biodiesel
2.6. Biodiesel blends
2.7. Feedstock
3. Chapter 3 : Biodiesel production
3.1. The process: Transesterification
3.2. Chemicals and equipment Required
1. Alcohol
2. Catalyst or lye
3. Vegetable oil
4. Equipment
3.3. Production of one batch of biodiesel
1.
Methoxide Preparation
2.
Transesterification
3.
Transfer and settling
4.
Separation
5.
Quality Testing
A. Wash Test
B. Methanol Test
6.
Water Washing
A. Mist washing
B. Bubble washing
C. Stir Washing
7.
Drying of biodiesel
8.
Washing with acids
9.
Wash water disposal
A. Some Biodiesel
B. Some excess Methanol
C. Catalyst ( lye)
D. Sulphur
E. Soap
10. Dry Washing or solid absorbent
11. Glycerine neutralisation
12. Recycling the wash water

1
2
3
7
9
12
13
13
14
14
15
16
17
18
19
19
19
20
20
20
21
21
21
21
21
21
22
22
23
23
23
23
24
24
24
24
24
24
25
25
25
25

4.

5.

6.
7.
8.

3.4. Effect of various factors

1.
Effect of lye or catalyst
2.
Effect of oil to alcohol ratio
3.
Effect of water and FFA
4.
Supercritical Process
5.
Membrane separation
6.
Effect membrane pores size
3.5. Advantages and disadvantages of transesterification
3.6. Safety
3.7. Various samples prepared and their result
Chapter 4: Properties Testing
4.1. Properties Testing
I.
Kinematic Viscosity
II.
Density
III.
Flash Point
IV.
Fire Point
V.
Calorific Value
4.2. Other important fuel properties
Chapter 5: Economic Analysis
5.1. Equipment cost
5.2. Feedstock cost
5.3. Cost analysis per litre of biodiesel
5.4. Potential cost reduction and recommendation
Chapter 6: Summary and conclusion
Appendix
References

25
25
27
27
27
28
28
29
29
30
31
31
33
33
33
35
36
38
38
38
39
40
43
46

Chapter 1
1.1 Abstract:
Reference [1]
The future global economy is likely to consume ever more energy, especially with the rising
energy demand of developing countries such as China and India. At the same time, the
tremendous risk of climate change associated with the use of fossil fuels makes supplying this
energy increasingly difficult.
We rely on coal, oil and gas (the fossil fuels) for over 80% of our current energy needs a
situation which shows little sign of changing over the medium-term without drastic policy
changes. On top of this energy demand is expected to grow by almost half over the next two
decades. Understandably this is causing some fear that our energy resources are starting to run
out, with devastating consequences for the global economy and global quality of life.
The potential for crisis if we run out of energy is very real but there is still time before that
occurs. In the past two decades proven gas reserves have increased by 70% and proven oil
reserves by 40%. At expected rates of demand growth we have enough for thirty years supply.
Moreover, better technology means that new oil and gas fields are being discovered all the time
while enhanced recovery techniques are opening up a potentially huge array of unconventional
sources, including tar sands, shale gas and ultra-deep-water. Ultimately, the near-unlimited
supply potential of renewable energy sources should ensure that the world does not fall short
of its energy needs.
How secure is our access to energy?
The security of global energy supplies continues to be problematic. Today, oil and gas reserves
are in the hands of a small group of nations, several of which are considered political unstable
or have testy relationships with large consuming countries. Eighty per cent of the worlds
proven oil reserves are located in just three regions: Africa; Russia and the Caspian Basin; and
the Persian Gulf. And more than half of the worlds remaining proven gas reserves exist in just
three countries: Russia, Iran, and Qatar.
Concerns over energy security prompt policymakers to seek independence from foreign
sources of energy. In Europe, new coal-fired power stations are back on the political agenda,
partly because Russia is no longer seen as a reliable supplier of gas. In the US, home-grown
biofuels have been promoted by successive administrations as an alternative to Middle Eastern
oil imports, despite being more expensive. These reactions are a natural consequence. The more
governments can extract themselves from the dependence on foreign energy resources, the
more secure they feel.
How does climate change affect the energy we use?
Emissions of carbon dioxide into the Earths atmosphere primarily as a result of burning
fossil fuels for energy are thought to be the cause of rising global temperatures. The scientific
evidence to support this assertion has become increasingly compelling in recent years,
suggesting a need for urgent and concerted action by all nations to prevent ecological
degradation on a massive scale.
For the first time in history we face an energy crisis not because we might run out of energy,
7

but because we are using it in the wrong way. Up to now the energy industry was judged by
two metrics: its contribution to energy security and the cost of energy delivered to the
consumer. To this we must now add a third: its success in reducing the emission of greenhouse
gases, chiefly carbon dioxide, into the atmosphere.
Fortunately, finding solutions to these differing energy crises demands a broadly similar
response:
Solution 1
Reduce growing energy demand through improved energy efficiency and conservation.
The first step to reducing global emissions is to arrest the growth in energy demand with an
aim to eventually setting it on a downward trend. The key for continued economic progress is
to learn how to create more wealth with less energy. This has additional benefits in improving
energy security, preserving precious natural resources and saving money for businesses and the
ordinary consumer.
However, unlocking the potential savings from improved energy efficiency will be very
difficult without government coordination to change consumer behaviour. This will involve
stricter product regulations as well as public education programmes to encourage people to
think differently about energy. Governments should also address the issue of financing,
providing cheap loans to households and small businesses with which they can carry out the
necessary improvement works.
Solution 2
Research, develop and deploy a broad range of energy sources, both domestic and international,
to work with properly functioning global markets to help meet future energy demands.

We need to look at both the short-term and long-term. In the short-term we can push existing
technologies to help reduce carbon emissions. Fortunately we already have many technologies
at our disposal: from wind, wave, solar and biomass for heat and power, to liquid biofuels,
biogas and electric motors for transport. In the long-term, evolutionary technologies need to be
further developed and research into revolutionary ones pursued.
A crucially important technology will be carbon capture and storage (CCS) which allows for
the continued use of fossil fuels in the future energy mix. Coal is widely used to generate
electricity in many of the worlds largest economies (especially the USA, China and India) and
without CCS technology there is little chance that their energy demands can be met whilst at
the same time reducing greenhouse gas emissions.
Solution 3
The so-called developed countries along with large developing countries such as China, India,
Russia and Brazil, should agree and adopt a common position on climate change, focused on
reducing greenhouse gas emissions through an effective cross-border market and technology
transfer mechanism.

Put simply, we cannot hope to avoid the dangerous consequences of climate change unless
global emissions are halved from current levels by 2050. At current rates of population growth
and with current technologies this will be impossible without a global agreement to limit and
disperse the negative consequences. Developed countries must shoulder the initial burden with
an agreement for immediate emissions cuts. In return, the largest developing countries must
agree to cut their own emissions in the future, but only after having achieved some recognisable
level of economic development.
All countries must agree to, and participate in, a carbon market framework with the aim of
reducing emissions where it is most efficient and least costly. At the same time they must
discover new renewable eco-friendly sources of energy and reduce their dependence on fossil
fuels.
With recent advancement in technology and intensive research and development a number of
various viable alternatives of conventional fuels are coming into light and biofuels are one
among these. Biofuels can be domestically produced and hence will reduce burden on imported
crude oil. At the same time it has high employment potential.

1.2 Scope of Project

Reference [2]
Energy is critical, directly or indirectly, in the entire process of evolution, growth and survival
of all living beings and it plays a vital role in the socio-economic development and human
welfare of a country. Energy has come to be known as a `strategic commodity and any
uncertainty about its supply can threaten the functioning of the economy, particularly in
developing economies. Achieving energy security in this strategic sense is of fundamental
importance not only to Indias economic growth but also for the human development objectives
that aim at alleviation of poverty, unemployment and meeting the Millennium Development
Goals (MDGs). Holistic planning for achieving these objectives requires quality energy
statistics that is able to address the issues related to energy demand, energy poverty and
environmental effects of energy growth.
A projection in the Twelfth Plan document of the Planning Commission indicates that total
domestic energy production of 669.6 million tons of oil equivalent (MTOE) will be reached by
2016-17 and 844 MTOE by 2021-22. This will meet around 71 per cent and 69 per cent of
expected energy consumption, with the balance to be met from imports, projected to be about
267.8 MTOE by 2016-17 and 375.6 MTOE by 2021-22.
Indias energy basket has a mix of all the resources available including renewables. The
dominance of coal in the energy mix is likely to continue in foreseeable future. At present
India's coal dependence is borne out from the fact that 54 % of the total installed electricity
generation capacity is coal based and 67% of the capacity planned to be added during the 11
Five year Plan period 2007-12, is coal based. Furthermore, over 70 % of the electricity
generated is from coal based power plants. Other renewables such as wind, geothermal, solar,
and hydroelectricity represent a 2 percent share of the Indian fuel mix. Nuclear holds a one
percent share.

In 2011-12, India was the fourth largest consumer in the world of Crude Oil and Natural Gas,
after the United States, China, and Russia. Indias energy demand continued to rise inspite of
slowing global economy. Petroleum demand in the transport sector is expected to grow rapidly
in the coming years with rapid expansion of vehicle ownership. While Indias domestic energy
resource base is substantial, the country relies on imports for a considerable amount of its
energy use, particularly for Crude Petroleum.
Table: 1

10

Table: 2

On the other hand, biodiesel can partially replace the use of diesel by mixing it with diesel in
proportion less than 20% and it can be used diesel powered vehicles with little modification in
piping and fitting. For example, Production of biodiesel has increased from about 25 million
gallons in the early 2000s to almost 1.1 billion gallons in 2012. This represents a small but
growing component of the annual U.S. on-road diesel market of about 35 billion to 40 billion
gallons. Reference [3].
In some cases it can fully replace and B100 can be used. The other notable advantage are it is
renewable, biodegradable eco-friendly and can be produced indigenously by using a wide
variety of feedstock like vegetable oils (both edible and non-edible) and animal fats. It has a
potential to harness the waste lands in India by planting non edible oil crops and trees and at
the same time it has very huge employment opportunities along with potential industrial
development. It has potential to save our foreign exchange and insure energy security. For
example, There are currently about 200 biodiesel plants across the country in USA from
Washington state to Iowa to North Carolina with registered capacity to produce some 3 billion
gallons of fuel. The industry is supporting more than 62,000 jobs, generating billions of dollars
in GDP, Reference [3].
No doubt, biodiesel has certain constraints too. The notable constraint is production cost per
litre which is generally higher than current diesel price. Hopefully it can be reduced by
intensive research and planning large scale production facilities.
Thus we can claim that biodiesel is a potent solution for a cleaner, greener and sustainable
tomorrow.
11

1.3 Objective of Project

In our project, we have put our efforts to explore and learn the process of making biodiesel
form various vegetable oils (both edible and non-edible oils). Mustard oil, soybean oil and palm
oil are edible oils and jatropha oil is the non-edible oil which is chosen for study. The overall
objective of the project can be described as
A.
B.
C.
D.

To study the various processes and equipment involved in the production of biodiesel.
To set up a small laboratory for producing it.
To produce biodiesel by using stated vegetable oils on academic scale.
To find out some of its (B100) properties (kinematic viscosity, density, flash point, fire
point and calorific value) experimentally and compare it with available data.

12

Chapter 2
2.1 Introduction

Three choices

Reference [4].

There are at least three ways to run a diesel engine on vegetable oil:
1. Mix it with petroleum diesel fuel, or with a solvent, or with gasoline;
2. Use the oil just as it is -- usually called SVO fuel (straight vegetable oil) or PPO fuel
(pure plant oil);
3. Convert it to biodiesel.
The first two methods sound easiest, but, as so often in life, it's not quite that simple.
1. Mixing it
Vegetable oil is much more viscous (thicker) than either petro-diesel or biodiesel. The purpose
of mixing or blending straight vegetable oil (SVO) with other fuels and solvents is to lower the
viscosity to make it thinner, so that it flows more freely through the fuel system into the
combustion chamber.
2. Straight vegetable oil (SVO).
Unlike biodiesel, which runs in any diesel without modification, you have to modify the engine
to use SVO.
3. Biodiesel or SVO?
Biodiesel has some clear advantages over SVO:

It works in any diesel, without any conversion or modifications to the engine or the fuel
system.
It also has better cold-weather properties than SVO (but not as good as petro-diesel).
Unlike SVO, it's backed by many long-term tests in many countries, including millions
of miles on the road.

2.2 Biodiesel:
Biodiesel refers to a non-petroleum-based diesel fuel obtained from biological sources
like vegetable oils and animal fats or triglycerides.
Technically Biodiesel refers to a non-petroleum-based diesel fuel consisting of long
chain of alkyl (methyl, ethyl or propyl) esters, made by transesterification of vegetable
oils or animal fats, which can be used (alone, or blended with conventional mineral
diesel) in unmodified diesel engine vehicles.

13

 The National Biodiesel Board (USA) also has a technical definition of "biodiesel" as a
mono-alkyl ester. Reference [5, 8].
Rudolf Diesel's prime model ran on its own power for the first time in Augsburg,
Germany on 10 August 1893 running on nothing but peanut oil. In remembrance of this
event, 10 August has been declared "International Biodiesel Day. Reference [5, 9].
Most major European vehicle manufacturers provide vehicle warranties covering the
use of pure biodiesel -- though that might not be just any biodiesel. Some manufacturers
insist on "RME", rapeseed methyl esters, and won't cover the use of soy biodiesel,
because soy biodiesel fails the EU biodiesel standard, EN 14214. Reference [4].
Germany has thousands of filling stations supplying biodiesel, and it's cheaper there
than petro-diesel fuel. Reference [4].
All fossil diesel fuel sold in France contains between 2% and 5% biodiesel. EU laws
will require this throughout Europe. Reference [4].

2.3 Physical Characteristic of Biodiesel

Table: 3
Reference [3]
Specific gravity
Kinematic viscosity at 40C, mm2/s
Cetane number
Higher heating value, Btu/gal
Lower heating value, Btu/gal
Density, lb/gal at 15.5C
Carbon, wt%
Hydrogen, wt%
Oxygen, by dif. wt%
Boiling point, C
Flash point, C
Sulphur, wt%
Cloud point, C

14

0.88
4.0 to 6.0
48 to 65
127,042
118,170
7.3
77
12
11
315-350
100-170
0.0 to 0.0024
-3 to 15

2.4 Physiochemical Properties of Methyl esters from various bio-oils.

Table: 4;
Serial
No.

Oil or fat

%Oil
content

AT 40C
Kinematic
Viscosity
(mm2/s)

Calorific
Value
MJ/kg

Reference [7, 11]

Cetane
Number

Cloud
point
(C)

Cold
filter
plugging
point
C

Flash
Point

Oxidation
Stability
(h), 110C

Density
(kg/m3)

Jatropha

3040

4.800

41.17

57.1

2.7

135

2.3

879.5

Karanza

35-40

3.99

35.56

57.6

12

160

---

880

Neem

4050

5.213

38.15

---

14.4

11

---

7.1

884.5

Mustard

4.5

37.25

52

156

879

Soybean

1520

4.039

40

52.00

1.0

-4

178

2.1

884.0

Sunflower

2535

4.439

39.3

49.00

3.4

-3

183

0.9

880.0

Palm oil

3060

5.700

34

62.00

13.0

12

164

4.0

876.0

Peanut oil

4555

4.900

40.1

54.00

5.00

17

176

2.0

883.0

Coconut

6365

2.726

56.7

0.0

-4

110

35.5

807.3

10

Mineral
Diesel

---

2.68

45-55

---

13

50-88

---

833

45.1

2.5 Advantages and Limitations of Biodiesel

Reference [3, 6, 13, 17]

Advantages:

Renewable, Bio degradable (5 times), Eco-friendly, Non-toxic.

Less Sulpher Content (1-2%) as compared to diesel (15%).
High Cetane Number (>45) and excellent lubricating property (higher engine life).
Less Flammable & higher flashpoint (>130C) as compared to diesel (52C).
Less Polluting HC, CO, CO2, Sulphur, Particulate matter, (except NOx),
High Lubricity, hence less engine wear.
Can be blended in any proportion with mineral diesel (B2, B5, B10, B20, B100 etc.)
Can be produced with a variety of biological sources (vegetable oil and animal fats).
Can be distributed through existing diesel fuel pumps and can be used without any
engine modification.

Limitations:
Less power per unit of fuel consumed as compared to mineral diesel.
High NOx emission.
Higher cloud point.

15

 Oxidatively less stable.

Material compatibility constraints. High density polyethylene, stainless steels and
aluminium are unaffected, but brass, zinc, tin, lead, and cast iron, natural rubber are not
compatible.

Figure Reference [13]

2.6 Biodiesel Blends:
Reference [6]
Biodiesel can be blended with mineral diesel in many different concentrations, for example.

16

B100 (pure biodiesel),

B20 (20% biodiesel, 80% mineral diesel),
B5 (5% biodiesel, 95% mineral diesel)
B2 (2% biodiesel, 98% mineral diesel).
B20 is a common biodiesel blend in the United States. Reference [6].

B5
Low-level biodiesel blends, such as B5 and B2 are ASTM approved for safe operation in any
compression-ignition engine designed to be operated on mineral diesel without any engine
modification. Reference [6].
B20
B20 is popular because it represents a good balance of cost, emissions, cold-weather
performance, materials compatibility, and ability to act as a solvent.
B20 and lower-level blends generally do not require engine modifications.
B20 has a higher cetane number (a measure of the ignition value of diesel fuel) and
higher lubricity (the ability to lubricate fuel pumps and fuel injectors) than mineral
diesel.
For B20, this could mean a 1% to 2% less energy per gallon than mineral diesel.
Reference [6].
B100
B100 contains about 8% less energy per gallon than petroleum diesel.
B100 increases nitrogen oxides emissions, although it greatly reduces other toxic
emissions.
B100 has a solvent effect and also it has poor cold weather performance (clogging of
filters).
B100 encounters material compatibility issues and requires equipment modifications
such as hoses and gaskets.
B100 is less common than B5 or B20 due to a lack of regulatory incentives and pricing.
Reference [6].
2.7 Feedstock
Biodiesel can be produced from a wide variety of vegetable oils (both edible and non-edible
oils) and animal fats. Some of notable feedstock are soybean, rapeseed, sunflower, corn,
coconut, peanut, palm, mustard oil, mahua, camelina, canola, cotton, pumpkin, jatropha curcas,
pongamina pinnata, sea mango, tallow (animal fat), poultry, used cooking oil, palanga, neem,
karanja, etc. Reference [13].

Rapeseed and soybean oils are most commonly used, soybean oil accounting for about
half of U.S. production. Reference [5,12].

Algae, grown on waste materials such as sewage, can be used for biodiesel production.
Reference [14].

Animal fats including tallow, lard, yellow grease, chicken fat, fish oil. Reference [15].

17

Chapter 3
Biodiesel Production
There are three basic routes to biodiesel production from oils and fats:

Base catalysed transesterification of the oil.

Direct acid catalysed transesterification of the oil.
Conversion of the oil to its fatty acids and then to biodiesel.

Almost all biodiesel is produced using base catalysed transesterification as it is the most
economical process requiring only low temperatures and pressures and producing a 98%
conversion yield. That is why we have chosen base catalysed transesterification process only
in this report. Reference [18].

3.1. The Process: Transesterification

Biodiesel is made from vegetable and animal oils and fats, or triglycerides. It cannot be
made from any other kinds of oil such as used engine oil. Reference [2].
Chemically, triglycerides consist of three long-chain fatty acid molecules joined by a
glycerine molecule.
The biodiesel process uses a catalyst (lye) to break off the glycerine molecule and
combine each of the three fatty-acid chains with a molecule of alcohol (methanol),
creating mono-alkyl esters, or Fatty Acid Methyl Esters (FAME) -- biodiesel.

Figure reference [16].

18

Figure reference [24].

3.2 Chemicals needed: Reference [4].

1. Alcohol: Biodiesel can be produced by using any of the fallowing alcohols.
1. Methanol, which makes methyl esters,
2. Ethanol (ethyl esters),
3. Isopropyl alcohol (isopropanol).
Methanol is poisonous so proper safety must be exercised.
Methanol must be 99+% pure.

2. Catalyst or Lye: can be either potassium hydroxide (KOH) or sodium hydroxide (caustic
soda, NaOH).
NaOH should be 97% pure.
19

Both KOH and NaOH are hygroscopic, which means they rapidly absorb moisture from
the atmosphere. Water makes them less effective catalysts: so always keep lye
containers sealed and air tight.
NaOH is cheaper to use.
KOH is a better catalyst all-round than NaOH. Commercially KOH is used to make
top-quality biodiesel.
KOH can also provide potash fertiliser as a by-product of the biodiesel process.
With KOH, the process is the same as with NaOH, but you need to use 1.4 times as
much (1.4025). Reference [4].
CAUTION:
Lye (both NaOH and KOH) is extremely caustic -- don't get it on your skin or in your
eyes, don't breathe any fumes, keep the whole process away from food.

3. Vegetable oil:
1.
2.
3.
4.
5.

Jatropha oil.
Mustard oil.
Soybean oil.
Mahua oil.
Palm oil.

4. Equipment:

A Magnetic stirrer: Capacity 2 liters, RPM range up to 1000, Temperature range

upto120C.
A separating funnel: Capacity 2 liters
A conical flask of capacity 2 liters.
Beakers of capacity 500ml, 250ml, conical flask of capacity 250 ml.
A thermometer of range up to 120C.
A digital weighing machine accuracy 1mg.
Funnel, distilled water etc.
3.3 Production of a batch of Biodiesel
Stuff: Reference [4]

1 litre of new vegetable oil.

200 ml of methanol, 99+% pure.
Catalyst or Lye, either potassium hydroxide (KOH) or sodium hydroxide (NaOH) can
be used, KOH is easier to use and it gives better results.
NaOH must be at least 97% pure, use exactly 3.5 grams.

With KOH it depends on the strength. If it's 99% pure (rare) use exactly 4.9 grams (4.90875).
If it's 92% pure (more common) use 5.3 grams (5.33), with 90% pure use 5.5 grams (5.454),
with 85% pure use 5.8 grams (5.775). Any strength of KOH from 85% or stronger will work.

20

Steps: Reference [4]

1. Methoxide Preparation
Take 200 ml methanol in a dry flask and 3.5 gm of 97% pure NaOH and dissolve it
completely by shaking. Lye will completely dissolve in the methanol, forming sodium
methoxide.

2. Transesterification

Take 1 liter of vegetable oil in a container (flask, beaker, HDPE container) and heat the
container to about 50oC-60oC at 600 rpm for 30 minutes on a magnetic stirrer.
Pour methoxide solution very slowly into the heated vegetable oil. Keep stirring for an
hour, while keeping the temperature at ~ 60oC and rpm 600.
Keep the temperature below 60oC since methanol will boil at 65oC and will be lost.
The reaction starts immediately, the mixture rapidly transforms into a clear, golden
liquid. Then allow the mixture to settle overnight.
The system should be closed to the atmosphere to prevent loss of methanol during the
reaction.
Sharma reported that increased in molar ratio of methanol to oil ratios beyond 6:1
neither increase the product yield nor the ester content, but rather makes the ester
recovery process complicated. Reference [25].

3. Transfer and Settling

As soon as the process is completed, pour the mixture into a separating funnel. Allow to settle
for 12-24 hours (longer is better).
4. Separation
Darker-coloured glycerine by-product will collect in a distinct layer at the bottom of the
funnel. Separate it by gravity separation method.
5. Quality Testing
Proceed to the wash-test and the methanol test to check the quality of your biodiesel.
A. Wash test

Put 150 ml of unwashed biodiesel (settled for 12 hours or more, with the glycerine
layer removed) in a half-litre glass or bottle.
Add 150 ml of water (at room temperature), screw the lid on tight and shake it up and
down violently for 10 seconds. Then let it settle.
The biodiesel should separate from the water in half an hour or less, with amber (and
cloudy) biodiesel on top and milky water below, and no more than a paper-thin white
interface layer between the oil and water.

21

B. Methanol Test
Jan Warnqvist of Sweden developed this extremely useful test, first introduced at the
Biofuel list in August 2005.
a. Take exactly 25 ml of biodiesel and dissolve it in exactly 225 ml of methanol
in a measuring glass.
b. The biodiesel should be fully soluble in the methanol, forming a clear bright
phase. If not, there is pollution in the biodiesel. Each ml of undissolved
material corresponds to 4% by volume. Is there any undissolved material at
the bottom of the measuring glass? If there is, your reaction is not complete
and this is causing you trouble with the water test.
If wash test is passed, wash it and use it with confidence. But if it fails process needs
improvement. The following are the causes of failures

Either too much catalyst and made excess soap, or

An incomplete reaction with poor conversion has left with half-processed
monoglycerides and diglycerides, fuel contaminants that also act as emulsifiers.

Remedies: more accurate measurements, better titration; longer processing time, better
temperature control, also try using more methanol.
6. Water Washing
If the test sample passes the quality tests then wash the rest of the biodiesel with
normal/ warm distilled water.
The main objective of biodiesel purification is to remove free glycerol, soap, salts,
excess alcohol, and residual catalyst.

Emulsion: Oil and water don't mix, and well-made biodiesel should separate quickly and
cleanly from the wash water when it settles. But if the biodiesel isn't made properly it will
contain half-processed oil molecules -- monoglycerides and diglycerides (MGs and DGs),
which are emulsifiers. Too much presence of emulsifiers will create problems during
water washing.

They cause injector coking and damage engine, especially with prolonged use.
No wash method should be used on any batch unless it is known for certain that
the reaction has completed.

Types of water washing

A. Mist washing: Mist-washing uses a fine spray above the wash-tank to send a mist of
water droplets down onto the surface, creating zero agitation. It is slow process and it
uses a lot of water, and usually the water is not re-used.
B. Bubble washing
It uses a small air-pump, usually an aquarium aerator pump with a bubble-stone. Water is added
to the biodiesel in the wash tank (usually a quarter to a half as much water as biodiesel) along
22

with bubble stone and switch on the pump. Air-bubbles rise through the water and into the
biodiesel, carrying a film of water around them, which washes the biodiesel around the bubble.
When it reaches the surface the bubble bursts, leaving the water to sink back down again,
washing the fuel a second time. It is very time taking usually three or four washes, each of six
to eight hours.

It's easy and doesn't take much effort.

Bubble-washing is gentle and can mask an incomplete reaction.
It takes a lot of time.
It causes fuel oxidation and polymerisation.
Polymerisation happens when the double bonds in unsaturated oil molecules are broken
by oxygen from the air or water.
Saturated oils don't polymerise, unsaturated oils do. The level of unsaturation is called
the Iodine Value (IV) -- the higher the IV, the more unsaturated the oil, the faster it
will oxidise and the more it will polymerise.
Without oxygen the oil can't oxidise and polymerise.
"The specification for biodiesel should include a limit on the tendency of the fuel to
oxidize and a limit on the maximum degree of oxidation allowable for use of the fuel
in diesel engines." Reference [19]

C. Stir washing

It employs a motor-driven impeller to mix the water-biodiesel mixture for about 5

minutes, until it looks homogenous.
Let it settle for 1 hour.
Drain the water from the bottom and repeat steps 4, 5 and 6 two more times.
Quick and effective, no masking of a poor reaction, no oxidation.

An alternative to stir washing is to use a small pump and a garden sprinkler.

7. Drying the biodiesel

Freshly washed biodiesel is often a bit cloudy. It should clear in a day or two. Leave it
in a sealed container out in the sun, or heat it to 45-50 deg C and let it cool in a vented
container.
If the biodiesel goes cloudy again after it's cooled. Give it another wash or heat it to
45-50 deg C a second time.
8. Washing with acids
Reference [25].
To neutralize the catalyst and split the soap from crude glycerine, strong hydrochloric
acid (HCl) is added.
Soap + Hydrochloric acid
Fatty acid + Salt.

As free fatty acids are not soluble in glycerine; so it can be easily separated using a
centrifuge.
23

Methanol can be removed by vaporization. Remainder impurities are salt. high free
fatty acid (FFA) during biodiesel production may cause obstruction to the separation of
methyl esters and glycerine.

Fatty acid + NaOH

Fatty acid + Methanol

Soap + Water.
H2SO4

ethyl ester + Water.

The acid based catalization slows the trans-esterification reaction. The two-step
approach of acid-catalysed esterification followed by base-catalysed transesterification gave a complete reaction at moderate temperature (50 to 61C).

9. Wash-water disposal

A.

B.

C.
D.

Wash-water may contain the following:

Some biodiesel
Biodiesel is not an environmental hazard: US Environmental Protection Agency
studies found that biodiesel is "more biodegradable than sugar and less toxic than
table salt".
Some excess methanol
Methanol is poisonous, but only for humans and monkeys.
"Methanol is a fixed-carbon nutrient source for plants." Reference [20].
Methanol is not viewed as an environmental hazard.
According to the United Nations Environment Programme (UNEP), the
International Labour Organisation (ILO) and the World Health Organization
joint International Programme on Chemical Safety, methanol is readily
biodegradable in the environment, in fact it might even be an advantage, some
of the waste-water digester bacteria like it. Reference [4].
The lye catalyst
Sulphur :
If acid-base process is used, the wash-water will contain some sodium sulphate or
potassium sulphate salt.
Sulphur is one of important plant "macro-nutrients. It's essential for plant growth, all
soils contain sulphur.

E. Soaps: Lye is commonly used as a drain-cleaner and presents no problems for waste-

water treatment systems, and domestic waste-water contains much soap, also no
problem for waste-water treatment.
10. Dry-washing or Washing with solid adsorbents :Reference [4, 25 ]

"Dry-washing" can be useful where water is scarce or expensive -- but it's not faster than
ordinary high-speed stir-washing, and it's not "more efficient" either. There are two types of
dry-washing compounds:
24

Absorbent such as Magnesol has the potential of selectively absorbing hydrophilic

materials such as glycerol and mono- and di-glycerides effectively.
Use of a solid absorbent, such as activated clay, activated carbon, activated fibre, etc.
purify the resultant biodiesel, followed by use of glycerine as a solvent to wash
impurities.
Activated carbon bed is an effective way to remove excessive biodiesel colour.
Ion-exchange resins: It removes all impurities (salts, soap, catalyst, glycerine and
water) from raw biodiesel following separation of the glycerine by-product.
11. Glycerine Neutralization
The glycerine by-product contains unused catalyst and soaps that are neutralized with an acid
and sent to storage as crude glycerine. In some cases the salt formed during this phase is
recovered for use as fertilizer. In most cases the salt is left in the glycerine. Water and alcohol
are removed to produce 80-88% pure glycerine that is ready to be sold as crude glycerine. In
more sophisticated operations, the glycerine is distilled to 99% or higher purity and sold into
the cosmetic and pharmaceutical markets.
12. Recycling the wash-water
The counter-current method of re-using the wash water reduces water use for three washes
by two-thirds.

3.4 Effect of Various Factors on Conventional Biodiesel Preparation Techniques

Effects of Catalyst:
1. Effect of Lye or catalyst: Reference [27].
There are two types of catalysts:
A. Alkali Homogeneous Catalysts ( NaOH , KOH) yields higher conversion of
vegetable oil to methyl esters in short time at lower temperature.
Drawbacks:
Energy intensive; recovery of glycerol is difficult; the catalyst has to be removed from
the product.
Alkaline wastewater requires treatment as free fatty acids (FFA) and water interfere
with the reaction and the presence of water lowers the activity of catalyst.
FFA react with the catalyst to produce saponified product. Soap renders biodiesel
purification and catalyst removal more challenging.
Fatty acid +NaOH

Soap + Water.

B. Heterogeneous catalysts (solid and enzymes) eliminates neutralization and washing

steps needed for processes used in homogeneous catalysts.
25

Drawbacks:

Higher temperature of trans-esterification reaction,

Longer reaction time and lower yield of esters.
High cost of the lipases as catalyst.
Heterogeneous catalysts such as H-Y zeolites, sulphated titanium oxides and cationexchange resin in the esterification of FFA and made use of calcium oxide and higher
methanol ratios in the trans-esterification and achieved biodiesel yield of 93%.
Comparison of homogeneously and heterogeneously catalysed
transesterification
Table: 5

Comparison of Homogeneous and Heterogeneous Catalysis:

Factors

Homogeneous Catalysis

Heterogeneous Catalysis

Catalysts

NaOH, KOH,

CaO, CaTiO3, CaZrO3, zeolite,

Al2O3, etc.

Reaction rate

Fast and high conversion

Moderate conversion

Yield (Purity of
methyl esters)

Higher close to 98 %

Less close to 80%

Post-treatment

Catalyst cannot be recovered

must be neutralized leading
to waste chemical production

Catalyst can be recovered

Processing
Methodology

Limited used of

Continuous fix bed continuous

methodology operation
possible

Presence of Water
and Free Fatty Acids

Sensitive

Not sensitive

Catalyst reuse

Not possible

Possible

Cost

Comparatively costly

Potentially cheaper

2. Effects of oil to alcohol ratio

Reference [27].

The lower the oil to alcohol ratio, the lesser the complexity of the separation and
purification processes vice versa.

26

Sharma reported that increased in molar ratio of methanol to oil ratios beyond 6:1
neither increase the product yield nor the ester content, but rather makes the ester
recovery process complicated.

3. Effects of water and free fatty acids

Reference [25].
Water present, at elevated temperatures, can hydrolyse the triglycerides to di-glycerides
and form an FFA, which causes soap formation in presence of base catalyst.

Fatty acid +NaOH

Soap + Water.

Presence of water at average temperatures leads to excessive soap formation which may
form a semi-solid substance that is very difficult to recover.
Demirbas reported that even a little amount of water (0.1%) in the trans-esterification
reaction will sufficiently reduce the methyl ester conversion from vegetable oil .

5. Esterification and trans-esterification without catalyst supercritical processes

Reference [27]
Esterification (180220 C) and trans-esterification reactions occur spontaneously at
high temperatures (>350 C).
Catalyst is not required.
Reaction rate is not affected by the presence of water.
Reaction rate is very high and it is possible to complete the reaction in less than 10
minutes.
Biodiesel Separation and Purification:
Ineffective biodiesel separation and purification causes severe diesel engines problems
such as plugging of filters, coking on injectors, more carbon deposits, excessive engine
wear, oil ring sticking, engine knocking, and thickening and gelling of lubricating oil.
The major limiting factor to biomass use is the technology development for the
separation, purification, and transformation of it into bio-chemicals and biofuels.
Currently, down-stream processing alone accounts for 60-80% of the process cost.
Biodiesel and glycerol produced are typically sparingly mutually soluble.
Density of biodiesel 880 kg/m3 and glycerol 1050 kg/m3, or more.
Gravitational settling or centrifugation for the separation of biodiesel and glycerol is
based on density differences.

6. Biodiesel Membrane Separation and Purification

Reference [27]
Minimization of higher capital cost and other related costs of production.
Provide higher specific area for mass transfer.
Made from inorganic micro-porous ceramic membranes such as membrane reactor and
separative ceramic membrane.

27

Membrane reactors can be employed to carry out a trans-esterification reaction as well

as separation and purification simultaneously.
Lower the thickness of membrane, the higher the productivity
Membrane performance is governed by: selectivity or separation factor and
permeability.
7. Effect of membrane pore size for biodiesel separation and
Purification
Reference [27]
It is important to estimate the minimum particle sizes in the vegetable oil-alcohol
emulsion for efficient refining process.
The average pore size for an oil emulsion was determined to be 44 mm with lower and
upper limits of 12 mm and 400 mm respectively.
The oil droplet was found not to pass through the membrane pores because of their
large molecular size relative to membrane pore size.
3.5 Advantages and Disadvantages of Transesterification
Table: 6
Reference [27]

Technologies

Advantages

Disadvantages

Trans-esterification

1.Fuel properties is
closer to diesel
2. High conversion
efficiency
3. Low cost
4. It is suitable for
industrialized
Production

1. Low free fatty acid and water

content are required (for base
catalyst)
2. Pollutants will be produced
because products must be
neutralized and washed
3. Accompanied by side reactions
4. Difficult reaction products
separation

Supercritical
Methanol

1.No catalyst
2. Short reaction time
(2-4min), less rxn lag.
3. High conversion
4. Good adaptability

1.High temperature and pressure

are required (above critical point).
2. Equipment cost is high
3. High energy consumption

28

3.6 Safety:
Reference [4]

Wear proper protective gloves, apron, and eye protection and do not inhale any
vapours.
Methanol can cause blindness and death. Sodium hydroxide and potassium hydroxide
can cause severe burns and death.
Mixed with methanol they form methoxide, This is an extremely caustic chemical.
Have a bottle of vinegar handy to neutralise any lye or methoxide you may get on
your skin -- rinse it off with vinegar, then rinse thoroughly with water. (If you don't
have any vinegar handy, just use lots of water.)
The workspace must be thoroughly ventilated.
Don't use "open" reactors -- biodiesel processors should be closed to the atmosphere,
with no fumes escaping.
All methanol containers should be kept tightly closed anyway to prevent water
absorption from the air.

Generally 80% of methanol in sewage systems is biodegraded within 5 days.

Methanol is a normal growth substrate for many soil microorganisms, which

completely degrade methanol to carbon dioxide and water.

3.7 Various Sample prepared and their Result

Table: 7
Sr.
No.

Date

Vegetable Oil

Methanol

NaOH

Preheating of
Vegetable oil at
600 RPM

Heating of
mixture of
Methoxide
Solution and
vegetable oil at
600 RPM

Settling
time

Water
washing

Oil name

Amount
(ml)

Amount
(ml)

Amount
(gm)

Time
(min)

Temp.
()

Time
(min)

Temp.
()

In
Hours

No of
Times

Remarks

3/3/14

Jatropha

500

125

2.5

130

65

10

60

36

Partial Success

4/3/14

Jatropha

500

125

2.5

60

65

60

60

24

Unsuccessful

26/3/14

Jatropha

1000

250

5.0

70

65

70

55

72

Unsuccessful

2/4/14

Jatropha

1000

250

5.0

60

65

60

55

72

Unsuccessful

4/4/14

Jatropha

100

30

0.5

170

65

50

10

Unsuccessful

6/4/14

Mustard

250

65

1.25

15

55

70

55

20

Successful

29

9/4/14

Jatropha

250

65

1.25

20

50

60

50

20

Partial Success

10/4/14

Mahua

250

65

1.25

20

50

60

55

20

Unsuccessful

14/4/14

Mustard

500

125

2.5

20

55

75

55

20

Successful

10

15/4/14

Mahua

250

65

1.25

20

50

60

55

20

Unsuccessful

11

16/4/14

Jatropha

1000

250

5.0

60

55

75

55

24

Unsuccessful

12

17/4/14

Mustard

1000

250

5.0

60

55

75

55

18

Successful

13

18/4/14

Soybean

250

65

1.25

20

55

60

55

12

Successful

14

21/4/14

Soybean

250

65

0.90

25

55

60

55

12

Successful

15

22/4/14

Jatropha

250

65

0.90

30

55

75

55

18

Successful

30

Chapter 4
4.1. Properties Testing

I.

Kinematic viscosity:

Viscosity is the property of fluid. It is defined as The internal resistance offered by the fluid
to the movement of one layer of fluid over an adjacent layer. It is due to the cohesion between
the molecules of the fluid.
It controls atomization and flow characteristics of fuel through the system. High viscosity may
lead to formation of soot and engine deposits due to insufficient fuel atomization. For good
quality fuel, kinematic viscosity should be as low as possible.
Measurement: Redwood viscometer

Figure Reference [21].

31

Formula Used: Reference [21].

Kinematic Viscosity ()

At

B/t

(in stokes or cm2/s).

Where
A

0.0026

1.72

time in seconds to fill 50 ml.

Observation:
Oil Temperature
Room Temperature

=
=

40 C
28 C
Table: 8
Kinematic Viscosity

Serial

Oil

Time to fill 50
ml oil (s)

Kinematic
viscosity
measured
(mm2/s)

Kinematic
viscosity (
Diesel as
reference)

Mineral Diesel

37.3

5.087

5.087

Palm Oil

249

64.05

Palm Biodiesel

46.5

8.39

5.087

Soybean Oil

176

44.78

Soybean Biodiesel

45

7.87

5.087

Mustard Oil

266

68.51

Mustard Biodiesel

46.6

8.42

5.087

Jatropha Oil

278

71.66

Jatropha biodiesel

42

6.82

5.087

Number

Note: We have taken our measured mineral diesel properties as reference, which is quite
different from standard values. This difference may be arising due reliability of equipment or
process of measurement.

32

II.

Density:

It is defined as the mass of fuel (substance) per unit volume. It plays important role during
gravimetric separation and water washing of biodiesel.
Observation:
Table: 9
Density
Serial
Number

Oil

Volume taken
(ml)

Mass
(gm)

Density
(kg/m3)

Ref.
Density
Kg/m3

Mineral Diesel

10

7.555

755.5

755.5

Palm Oil

4.404

888.08

Palm Biodiesel

4.183

836.6

755.5

Soybean Oil

5.1

4.428

868.2

Soybean
Biodiesel

4.286

857.2

755.5

Mustard Oil

10

8.560

856.0

Mustard
Biodiesel

10

8.034

803.4

755.5

Jatropha Oil

10

8.535

853.5

Jatropha
Biodiesel

10

7.996

799.6

755.5

Note: We have taken our measured mineral diesel properties as reference, which is quite
different from standard values. This difference may be arising due reliability of equipment or
process of measurement.
III.

Flash point: It is the lowest temperature at which a volatile fuel vaporizes

sufficiently in air and forms an ignitable mixture. Measuring flash point requires an
ignition source. At the flash point, the vapour may cease to burn when the source of
ignition is removed. It is used to assess the overall flammability hazard of a material.
For good quality fuel, flash point should be moderate.

IV.

Fire point / Auto-ignition temperature: The fire point of a fuel is the temperature at
which it will continue to burn for at least 5 seconds after ignition by an open flame. At

33

the flash point, a lower temperature, a substance will ignite briefly, but vapour might
not be produced at a rate to sustain the fire. Mostly authors list material flash points,
but in general, the fire points can be assumed to be about 10 C higher than the material
flash points. For good quality fuel, fire point should be moderate.
Note: Neither the flash point nor the fire point is dependent on the temperature of the
ignition source, which is much higher.

Figure Reference [23].

34

Observation:
Table: 10
Flash Point and fire Point
Serial
Number
1
2
3
4
5

V.

Oil
Mineral Diesel
Soybean Biodiesel
Palm Biodiesel
Mustard Biodiesel
Jatropha Biodiesel

Flash Point
C
65
193
178
165
143

Fire Point
C
72
220
192
175
152

Flash Point C
Reference []
50-88
178
164
156
135

Calorific Value: The amount of heat produced by unit quantity of fuel when it under
goes complete combustion in presence of air. The caloric value of biodiesel is lower
than of diesel because of its higher oxygen content. For good quality fuel, calorific value
should be as high as possible.
Measurement: Bomb Calorimeter

Figure Reference [22].

35

Observation:
Water temperature at room temperature

Mass of water taken in bomb Calorimeter

Mass of fuel taken in bomb calorimeter

Water equivalent of bomb calorimeter

Specific heat capacity of water

28C

4.187 kJ/kg-K.

Table: 11
Calorific Value
Serial
Oil
Number

Initial
Temp.(C)

Final Temp.
(C)

Experimental
Calorific
Value
(MJ/kg)

Reference
Calorific
value
(MJ/kg)

Mineral Diesel

45.1

Soybean Biodiesel

40

Palm Biodiesel

34

Mustard Biodiesel

37.25

Jatropha Biodiesel

41.7

4.2. Other Important Fuel Properties

Cloud point: It is the temperature at which a cloud of wax crystals first appear when
the fuel is cooled under controlled conditions during a test. The utilization of fuel is
restricted to the temperature above their cloud point. For good quality fuel, cloud point
should be as low as possible.
Cetane number (CN): Cetane number is a measure of the ignition quality of fuel
during compression ignition. It provides information about the ignition delay time of a
fuel upon injection into the combustion chamber. High CN implies short ignition delay,
hence better fuel. For good quality fuel, CN should be as high as possible.
Oxidation stability: It ability of a fuel or any material to resist natural degradation
upon contact with oxygen. The products of oxidation can cause damage to combustion
36

engines. This is why oxidation stability is an important quality criterion for biodiesel,
which needs to be regularly determined during production. For good quality fuel,
oxidative stability, should be higher.
.
Sulphur content: Combustion of fuel containing sulphur causes emissions of sulphur
oxides.(SOx). Most of vegetable oils and animal fat-based bio- diesel have very low
levels of sulphur content. However, specifying this parameter is important for engine
operability as sulphur is corrosive in nature and causes corrosion, wear and tear. For
good quality fuel, sulphur content should as low as possible.
Water and sediments content: The presence of water and sediment has two forms,
which are either dissolved water or suspended water droplets. While bio- diesel is
generally considered to be insoluble in water, it actually takes up considerably more
amount of water than diesel fuel. Water content in biodiesel reduces the heat of
combustion and will cause corrosion of vital fuel system components like, fuel pumps,
injector pumps, fuel tubes, etc. Moreover, sediment may consist of suspended rust and
dirt particles or it may originate from the fuel as insoluble compounds formed during
fuel oxidation. For good quality fuel, water and particulate matter should be as low as
possible.
Flammability: How easily fuel (substance) will burn or ignite causing fire or
combustion. For good quality fuel, flammability should be moderate.
Iodine Value (IV): Polymerisation happens when the double bonds in unsaturated oil
molecules are broken by oxygen from the air or water. Saturated oils don't polymerise,
but unsaturated oils do. The level of unsaturation is called the Iodine Value (IV) -- the
higher the IV, the more unsaturated the oil, the faster it will oxidise and the more it will
polymerise .Without oxygen the oil can't oxidise and polymerise.

37

Chapter 5
Economic Analysis:
5.1 Equipment cost
Table: 11
Serial
Number

Equipment/Feedstock

1
2
3
4
5
6
7
8
9
10
11

Magnetic Stirrer
Separating Flask
Beakers (1000 ml)
Beakers (200 ml)
Conical Flask
Funnel
Aluminum foil
Gloves
Thermometer
Lye (NaOH)
Container
Total

Cost per
No.
equipment/feedstock
Rs.
6096
1
2800
1
209
2
45
4
45
2
15
4
50
1
35
3
75
1
250
120
2
=
10364 Rs.

Total
cost
Rs.
6096
2800
418
180
90
60
50
105
75
250
240

5.2 Feedstock cost

Table: 12
Serial
Number
1
2
3
4
5
6
7

Feedstock
Jatropha oil
Mustard oil
Mahua oil
Palm oil
Soybean oil
Distill Water
Methanol
Total

Other expenses (transportation) =

Total Cost of the project
=

Cost/liter
50
98
120
70
120
4
460
=

Quantity
Liter
10
4

30
3
2582 Rs.

Total
500
392
60
70
60
120
1380

Rs. 576
Rs. 13522

5.3 Cost analysis for production of one batch of biodiesel from various vegetable oil
Cost of one batch of biodiesel consist of cost incurred in various steps. This can be listed
as the cost of following ingredients:
1. 250ml of vegetable oil,
38

2.
3.
4.
5.

65ml of methanol,
0.90 gm of NaOH,
Energy cost (electricity).
Water washing .
Table: 13

Serial
Number

1
2
3
4
5

Vegetable
oil

Jatropha oil
Mustard oil
Mahua oil
Palm oil
Soybean oil

Cost of
250ml of
Vegetable
oil
Rs.
12.5
24.5
30
17.5
30

Cost of
65ml of
Methanol
Rs.
30
30
30
30
30

Cost of
0.90gm
of NaOH
Rs.
0.625
0.625
0.625
0.625
0.625

Yield

Total cost

ml

Rs.

Cost/Litre
of biodiesel
produced
Rs.

200
235
230
220

43.125
55.125
48.125
60.625

215.625
234.57
209.25
275.5

5.4. Potential Cost Reduction Recommendations:

Glycerine processing: Glycerol can be recovered for multiple purpose like heating,
soap industries, pharmaceuticals.
Alcohol recovery: Alcohol can be recovered from glycerine and further reused.
Wash water recovery: Nearly two- third of wash water can be recovered and reused
for further washing.
Catalyst recovery.
Use of cheaper feedstock.
Use of barren land for plantation of non-edible crops like jatropha.
Use of cheaper sources of energy input like sun light since temperature requirement is
less than 65C.
Use of variety of feedstock.
Research and development for new and cheaper ways for production.
Development of new catalyst for faster reaction and quick settling, etc.

39

Chapter 6 : Summary and Conclusion:

Block Diagram for production of biodiesel

Figure Reference [28].

40

Figure Reference [24].

Alternative fuels are gaining in importance due to unstable crude oil prices and the
consequences of emissions deriving from crude oil compounds. Biodiesel is an increasingly
attractive, non-toxic, environmental friendly, biodegradable fuel alternative that can be
produced from a variety of renewable sources with almost similar processes. Of the various
methods available for producing biodiesel, the alkali catalysed transesterification of vegetable
oils and animal fats is currently the most commonly adopted method. The transesterification
reaction requires an alcohol as a reactant and a catalyst. The most commonly used alcohol is
methanol while sodium hydroxide and potassium hydroxide are the most commonly used
catalysts. This method of catalysis is preferable to others because of its high yield and relatively
low installation costs. During the reaction, glycerol will be produced as a by-product. Because
of its numerous industrial applications, the crude glycerol can be refined with purity higher
than 99% to make it usable. There are four primary factors affecting the yield of biodiesel, i.e.
alcohol quantity, reaction time, reaction temperature, and catalyst concentration. To ensure a
complete transesterification reaction, the molar ratio of alcohol to triglycerides should be
increased to 6:1 with the use of an alkali catalyst. The optimal temperature ranged between
50 and 60, depending on the oil used.
It is true that the cost involved in per litre production of biodiesel is more than commercially
available mineral diesel. Also, there are certain other issues like material compatibility, cold
41

weather performance, cold staring, storages because of oxidation, lower calorific value, etc.
Most of which can be mitigated by using appropriate additives.
For cost, it can be reduced by various improvements in the process like.
Glycerine processing: Glycerol can be recovered for multiple purpose like heating,
soap industries, pharmaceuticals.
Alcohol recovery: Alcohol can be recovered from glycerine and further reused.
Wash water recovery: Nearly two- third of wash water can be recovered and reused
for further washing.
Catalyst recovery.
Use of cheaper feedstock.
Use of barren land for plantation of non-edible crops like jatropha.
Use of cheaper sources of energy input like sun light since temperature requirement is
less than 65C.
Use of variety of feedstock.
Research and development for new and cheaper ways for production.
Development of new catalyst for faster reaction and quick settling, etc.
Note: Germany has thousands of filling stations supplying biodiesel, and it's cheaper
there than petro-diesel fuel. Reference [4].
With increasing concern over global warming, it is foreseeable that biodiesel usage
would continue to grow at a fast pace. This will trigger the development of more
sophisticated methods of biodiesel production and refining to cope with the increasing
market demand and save nature around us.
It can be said, Biodiesel is the potential alternative fuel for cleaner, greener and
sustainable tomorrow.

42

Appendix:

Vegetable oil yields: Reference [17]

Ascending order

Alphabetical order

Crop

Litres
oil/ha

US gal/acre

Crop

Litres oil/ha

US gal/acre

Corn
(maize)

172

18

Avocado

2638

282

Cashew nut

176

19

Brazil nut

2392

255

Oats

217

23

Calendula

305

33

Lupine

232

25

Camelina

583

62

Kenaf

273

29

Cashew nut

176

19

Calendula

305

33

Castor bean

1413

151

Cotton

325

35

Cocoa
(cacao)

1026

110

Hemp

363

39

Coconut

2689

287

Soybean

446

48

Coffee

459

49

Coffee

459

49

Coriander

536

57

Linseed
(flax)

478

51

Corn
(maize)

172

18

Hazelnut

482

51

Cotton

325

35

Euphorbia

524

56

Euphorbia

524

56

Pumpkin
seed

534

57

Hazelnut

482

51

Coriander

536

57

Hemp

363

39

Mustard
seed

572

61

Jatropha

1892

202

Camelina

583

62

Jojoba

1818

194

Sesame

696

74

Kenaf

273

29

43

Safflower

779

83

Linseed
(flax)

478

51

Rice

828

88

Lupine

232

25

Tung oil

940

100

Macadamia
nut

2246

240

Sunflower

952

102

Mustard
seed

572

61

Cocoa
(cacao)

1026

110

Oats

217

23

Peanut

1059

113

Oil palm

5950

635

Opium
poppy

1163

124

Olive

1212

129

Rapeseed

1190

127

Opium
poppy

1163

124

Olive

1212

129

Peanut

1059

113

Castor bean

1413

151

Pecan nut

1791

191

Pecan nut

1791

191

Pumpkin
seed

534

57

Jojoba

1818

194

Rapeseed

1190

127

Jatropha

1892

202

Rice

828

88

Macadamia
nut

2246

240

Safflower

779

83

Brazil nut

2392

255

Sesame

696

74

Avocado

2638

282

Soybean

446

48

Coconut

2689

287

Sunflower

952

102

Oil palm

5950

635

Tung oil

940

100

44

Oils and esters characteristics: Reference [17]

Oils and esters characteristics

Type of Oil

Melting Range deg C

Iodine
number

Cetane
number

Oil / Fat

Methyl
Ester

Ethyl
Ester

Rapeseed oil, h.
Eruc.

-2

97 to 105

55

Rapeseed oil, i.
Eruc.

-5

-10

-12

110 to 115

58

Sunflower oil

-18

-12

-14

125 to 135

52

Olive oil

-12

-6

-8

77 to 94

60

Soybean oil

-12

-10

-12

125 to 140

53

Cotton seed oil

-5

-8

100 to 115

55

Corn oil

-5

-10

-12

115 to 124

53

Coconut oil

20 to 24

-9

-6

8 to 10

70

Palm kernel oil

20 to 26

-8

-8

12 to 18

70

Palm oil

30 to 38

14

10

44 to 58

65

Palm oleine

20 to 25

85 to 95

65

Palm stearine

35 to 40

21

18

20 to 45

85

Tallow

35 to 40

16

12

50 to 60

75

Lard

32 to 36

14

10

60 to 70

65

45

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Mohammad Mashudb, Md. Rowsonozzaman Rubelb, Rakibul Hossain Ahmadb

46

26)

Lujan JM, Bermudez V, Tormos B, Pla B. Comparative analysis of a DI diesel

engine fuelled with biodiesel blends during the European MVEG-A cycle:performance
and emissions (II). Biomass Bioenergy 2009;33:948e56.

27)

Overview on the current trends in biodiesel production N.N.A.N. Yusuf, S.K.

Kamarudin Z. Yaakub
28) www.qrbiz.com.

47