Why value addition for by products? • To reduce the actual cost of biodiesel • To provide raw material to Bio fuel allied industries • Create self employment in rural areas(small scale home industries)
Actual cost of biodiesel without utilisation of by-products. • Cost of 200 kg seeds @ 17/kgs and transport charge= 3700.00 • Oil extraction cost • From 200kgs of pongamia seed yield 50 liter oil. • Expeller: for crushing 200 kgs seed require 12 hrs 12 Hrs ×5hp= 45 units 45×6.00/unit = 270 .00 • Labor charge: 200.00 Rs/per batch • Total cost for 50liter oil extraction process : raw material + oil extraction cost: 3970.00
Transesterification process: Raw material required for each biodiesel batch Maetrial
Quantity
Methanol NaOH
13.5 liter 300g
Electricity required for 1 batch
13.5 unit
Labour
1day
Rupees per kg 50.00 80.00 6.00 Rs / unit
Amount 675.00 37.00 81.00 300.00
Total
1093.00
Total cost of biodiesel production for each batch cost of oil extraction+ biodiesel production 3970.00+ 1093.00 = 5063.00 Yield of biodiesel / batch: 42 liter Actual Cost of biodiesel per liter= Rs 120.00/ liter!!!
Value Addition for Seed Shell Bio fuel seeds are generally coated with a protective layer called shell. Seed shell is removed manually or by using decorticator before oil extracton. The seed shell can be a raw material for value added products: 1. Fuel Briquettes and pellets . 2. Vermi compost 3. Powdered agricultural manure. 4. Composite laminates For example : Cost of Pongamia pod/kg: Rs 6.00 For 10 kg Pongamia pods: shell weight 4.5 to 5.0 kgs. Market value for vermi compost : Rs 10-12 /kgs
Value Addition for Seed pulp In few Biofuel species the seed is covered with pulpy material. for example- simarubha, coccum etc, these pulpy material can used for medicinal and other value added products. 1. Soft drink preparation 2. Ethanol production by fermentation 3. Biogas production 4. Simarubha seed pulp is said to have medicinal value and is being used in Cough, hepatitis, and cancer treatments
Value Addition for Oil Cake Oil cake is obtained as a main by product after extracting oil from the seed. Oil cake contain few toxic elements and hence can not be used as fodder. But it has other uses. 1. Manure. Market value around Rs.20/kg. 2.
Biogas production.
3.
Toxic component present in cake can be separated and used as insecticidal agent.
4.
Blended organic manure
5.
Detoxified of oil cake can be used as fodder.
Vermi composting • Byproducts such as seed shell, oil residue can also used for vermi composting.
Vermicompost pit at JNNCE, Shimoga
Use of cake for biogas production • One can have the cake and eat it too!!! (Gas and manure) • Methane gas present in biogas can be further converted into Methanol Experiments at our center
Volume of gas in liter
Quantity of feed 1.0 kgs 800 600 400
single digester
200
double digester
0 1
3
5 7 9 11 13 15 Number of days
The crude glycerol contains mainly methanol, biodiesel and unreacted oil. Concentration of glycerol content is 40 to 60% Crude glycerol can be utilized 100 % in house to produce valuable products. Organic soap and Hand Wash. Oil residue can used for biodiesel production. pure glycerol in food, pharmaceutical, cosmetics, and many other industries
Biodiesel can also produced from oil residue contained in crude glycerol by treating it with acid followed by transesterification process. 1 hr stirring H2SO4 10 ml and allow to 1 lit Crude saperate glycerol Methanol 100 ml
Oil residue
Collect oil layer Impurities
biodiesel
Transesterification
Find FFA
Crude glycerol to Ethanol Conversion • Crude glycerol can also by converted to ethanol by bacterial degradation using E.coli and fungus such as Saccharomyces cerevisiae • Studies in this direction are going on in our I&D Center in collaboration with local diagnostic center.
Purification of crude glycerol to Pharmaceutical grade • Crude glycerol can purified to recover pure from glycerol by removing unreacted oil, salts and followed by solvent extraction and de coloration process. Ecnomics: Cost of crude glycerol per liter: Rs 25-30.00 Purified from of glycerol IP or BP grade : Rs 180190.00 per liter
Glycerol Purification at our I&D center
Acid Treatment To separate oil layer
Activated charcoal treatment for De coloration
Methanol Treatment to separation salt
Filtration and removal of Methanol
Value for Biodiesel with use of Byproducts • Actual cost of biodiesel without use by products for batch: Rs 5063.00 • Actual cost of biodiesel without use byproducts : Rs 120.00 / liter Utilization of by products 1. From oil cake : Rs-2800.00 2. From glycerol soap: Rs-1008.00 Total income: Rs-3808.00 Cost for biodiesel = Total cost of biodiesel production per batch- Total income 5063.00 – 3808.00 = 1255.00 Cost of biodiesel per liter – 1255.00/42.0 = Rs 30.00/ liter
IS BIODIESEL A PRODUCT OR BY PRODUCT?