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Red sea university Journal of Basic and Applied Science ISSN: 1858 -7690 (Online)

Vol. 2 Special Issue (1) - March 2017 ISSN: 1858 -7658 (Print)

Simulation of Jatropha Biodiesel production using SuperPro


Designer

Mohamed Ismaiel Mohamed Hamid 1 *, Kamil M.Wagialla 2

1. Department of chemical engineering, Khartoum university, Sudan


2. Engineering college, International University of Africa and Khartoum University, Sudan
* abushaya7@hotmail.com

Abstract
This research work is about the production of biodiesel from jatropha oil on a commercial
scale. Jatropha was chosen because it is not edible therefore, it will not pose a problem to
humans in terms of food competition. A SuperPro Designer V.7.0 was used to simulate the
design of jatropha biodiesel plant.The process was fully outlined. Analysis and review of the
results showed the variation of production cost over the range from 15000 to 300000 MT/
yr of biodiesel from Jatropha oil per year . The analysis assumes that a new facility will be
built for this process, and the project lifetime is 15 years. One of the most important findings
of this study is that biodiesel price is compatible with diesel fuel world price of about 800 $/
ton to 1200 $/ton ,while Jatropha biodiesel unit production cost is about 520 to 1040 $/ton
depending on production rate. At production rate 300000 MT/yr will the amount of Sudan
diesel import will minimized by 11%. Recycling of crude Jatropha oil and methanol proved
both cost-effective and environmentally friendly.

Keywords: Biodiesel production, Jatropha, Simulation, SuperPro Designer

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Introduction Through the transesterification


Abundant and economical energy process of the vegetable oils,
are the life blood of modern animal fats or recycled greases can
civilizations. However, the global be converted into biodiesel. It is a
energy consumption is growing clean and renewable fuel which is
faster than the increase in the suitable as the alternative fuel for
population. World-wide fuel fossil diesel. Biodiesel industry is
consumption increased from 6,630 still in its infancy but is growing
million tons of oil equivalent (M ton) rapidly. The world total biodiesel
in 1980 to 11,295 (M ton) in 2008 . It production in 2007 was reported to
is forecasted by International Energy be 8.4 million tons which increased
Agency that the global energy to 20 million tons in 2010 and it is
consumption would increase 53% by predicted to reach 150 million tons
2030. Fossil fuels have significantly by 2020. However, variability in
contributed to harmful emissions the feedstock, fossil fuel price and
and climate change. Carbon dioxide the demand of biodiesel have given
(CO2), nitric oxide (NO), volatile rise to instability within the industry.
organic compounds (VOC) and These factors have influenced the
hydrocarbons (HC) are the main economic viability of biodiesel at a
air pollutants which result from the global scale. Currently, 95% of the
fossil fuels combustion. world biodiesel production is from
Therefore, the greenhouse gas edible oil that is easily available on
mitigation strategies are taken a large scale from the agricultural
into consideration in recent efforts industry. Since there is a competition
on the development of global between the food and fuel market,
environmental issues, research this makes the focus shifted to non-
and urban planning. Biodiesel is edible oil like jatropha curcas as
one of the significant solutions for feedstock for biodiesel production
oil shortage and global warming. [1].

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Vol. 2 Special Issue (1) - March 2017 ISSN: 1858 -7658 (Print)

Sudan energy consumptions aviation biofuel to have a share of


scenarios the aviation fuel market by 2024 [2].
Sudan’s energy demand has Biodiesel
significantly grown through the past Biodiesel is defined as the mono
20 years from 6.8 MT to more than alkyl esters (methyl and ethyl esters)
11.2 MT . Crude oil is the main source of long chain fatty acids derived
of fossil energy and its consumption from vegetable oils or animal fats,
has rapidly increased in recent for use in compression-ignition
years owing to the increase in the (diesel) engines. It is formed from
country’s economic and population transesterification of vegetable oils
growth Biomass contribution has with methanol (or ethanol). Biodiesel
significantly dropped due to high has many merits as a renewable
growth in hydro and oil source. energy resource that include
The main source of biomass is being derived from a renewable,
wood (83%) in the form of raw and domestic resource, thereby relieving
processed wood (charcoal) which reliance on petroleum fuel, and it
highly affects the green area and leads is biodegradable and non-toxic.
to deforestation in the country. The Furthermore, compared to petroleum-
transportation sector is the largest based diesel, biodiesel has a more
user of the refined fuel products, favorable combustion emission
consuming about 61% from the total profile, such as low emissions of
crude oil volume presently produced. carbon monoxide, particulate matter
The major fuel form used is diesel. and unburned hydrocarbons. In
It represents about 50% of the total addition, using biodiesel on a large
fuel consumption, whilst gasoline scale will promote plantations of
and jet A1 represent 23% . crops used to produce its feedstock.
The target of the Sudan Biofuel This would result in more carbon
roadmap is to introduce a certified dioxide recycling by photosynthesis,
biojet fuel by 2018, and for this thereby minimizing the impact of

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Vol. 2 Special Issue (1) - March 2017 ISSN: 1858 -7658 (Print)

the greenhouse effect. Biodiesel has lower negative impact on biodiversity


a relatively high flash point (150 C), o
than if planted as plantations.
which makes it less volatile and safer From a development perspective,
to transport or handle than petroleum decentralized production and use of
diesel. It provides lubricating Jatropha oil from low-technology
properties that result from the free processing and use for provision of
fatty acids present, which reduce electricity is appealing. The idea of
engine wear and extend engine life. having a multi-functional platform
Furthermore, biodiesel has physical (MFP) running on Jatropha oil is that
properties and energetic content close the community can be self supplied
to those of petroleum diesel, which with fuel for providing electricity
allows it to function efficiently in and mechanical power for grinding
conventional diesel engines without maize and pressing oil seeds, thereby
any modifications [3]. increasing local energy security. It
Jatropha curcas would also provide farmers with an
Jatropha curcas ,commonly known additional source of income [4].
as Jatropha, belongs to the family The chemical reaction for base-
Euphorbiaceae and is native catalyzed biodiesel production is
to tropical America, but grows depicted below.
throughout the tropics. Jatropha
seeds contain 27– 40% inedible oil,
which can be converted into biodiesel
or be used straight or as blends in
appliances ranging from stoves to
engines. It can be used as a fence to
protect crops from grazing livestock,
and if planted as hedges it does not
compete with food production over
land. Planting as hedges also has

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It is a reversible reaction so the been mixed with methanol. R’,


short chain alcohol, signified by R’’, and R’’’ indicate the fatty acid
ROH (usually methanol, but chains associated with the oil or fat
sometimes ethanol) is charged in which are largely palmitic, stearic,
excess to ensure quick conversion. oleic, and linoleic acids for naturally
The catalyst is usually sodium or occurring oils and fats.
potassium hydroxide that has already

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Figure 1: production of biodiesel [5]

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Figure 2: Biodiesel production from Jatropha oil –Methanol


recovery system flow sheet
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Table 1 Streams specifications


Stream Flow rate
Components Temperature ( )
number (kg/h)
Methanol
S - 101 53.07029 50
NAOCH3
S – 102 Methanol 412.79013 25
Methanol
S – 103 707.82097 64.75
Water
S – 104 jatropha oil 4246.81502 60.00
Methanol ,NAOCH3
S – 105 760.891 64.75
Water
Diesel , Glycerin
S – 106 741.987 25
Methanol ,NAOCH3
Diesel, Glycerin
HCl, jatropha oil,
S – 107 4915.285 25
Methanol, Sodium
Chloride , Water
Diesel, Glycerin, HCl,
S – 108 jatropha oil, Methanol, 1412.774 30.77
Sodium Chloride, Water
Diesel, Glycerin, HCl,
S – 109 jatropha oil, Methanol, 1412.774 30.83
Sodium Chloride, Water
S – 110 Water 166.08000 25.00
S – 111 HCl, Water 7.067 25
S – 112 HCl, Water 173.147 25
Diesel, Glycerin, HCl,
S – 113 jatropha oil, Methanol, 4267.715 37.22
Sodium Chloride, Water
S – 114 Glycerin, Methanol, Water 169.571 100
Methanol, NAOCH3,
S – 115 760.891 64.75
Water
Diesel, Glycerin, HCl,
S – 116 jatropha oil, Methanol, 476.419 31.5
Sodium Chloride, Water
S – 117 HCl, Water 23.217 25
Diesel, Glycerin, HCl,
S – 118 jatropha oil, Methanol, 936.355 31.5
Sodium Chloride, Water
Diesel, Glycerin,
S – 119 741.987 25
Methanol, NAOCH3
S – 120 Sodium Hydroxid 1.802 25

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S – 121 Sodium Hydroxid 1.80244 25.04


Diesel, Glycerin, HCl,
S – 122 jatropha oil, Methanol, 647.57 37.22
Water
Diesel, Glycerin, jatropha
oil, Methanol, Sodium
S - 123 938.157 31.49
Chloride, Sodium
Hydroxid, Water
Diesel, Glycerin, jatropha
oil, Methanol, Sodium
S - 124 938.157 31.54
Chloride, Sodium
Hydroxid, Water
Diesel, Glycerin, jatropha
oil, Methanol, Sodium
S – 125 938.157 80.56
Chloride, Sodium
Hydroxid, Water
Diesel, Glycerin, jatropha
oil, Methanol, Sodium
S – 126 643.126 100
Chloride, Sodium
Hydroxid, Water
Diesel, Glycerin, jatropha
oil, Methanol, Sodium
S – 127 643.126 100.04
Chloride, Sodium
Hydroxid, Water
Diesel, Glycerin, HCl,
S – 128 jatropha oil, Methanol, 4723.234 57.11
Sodium Chloride, Water
S – 129 Methanol, Water 295.031 90
Diesel, Glycerin, jatropha
oil, Methanol, Sodium
S - 135 473.556 127
Chloride, Sodium
Hydroxid, Water

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Methodology One Reactor System


This simulation analyzes the Reaction Section
production of about 15000 to The reaction section consists of:
300000 metric tons (MT) per year • Reactor (V-101 )
of biodiesel using jatropha oil by • A centrifugal separator (DC-101)
scaling up the plant 20 times. flow The jatropha oil which is produced
sheets, tables and graphs created by by machinery pressing or solvent
using SuperPro and MATLAB . extraction from Jatropha seeds is
Below is a brief description of directly fed to reactor (V-101).
the basic features of the biodiesel Methanol and the catalyst are mixed
process . and fed to the reactor. According
Design cases to the reaction mentioned earlier,
For simplification purposes the methanol reacts with jatropha oil and
process has been split into three yields biodiesel and glycerol. The
sections: the Reaction (red icons), product is removed at a rate equal
the Biodiesel Refining (green icons), to the rate of charging the reactants
and the Glycerol Purification (blue and catalyst. The average residence
icons) section. A section in SuperPro time of materials in the reaction is
is simply a set of unit procedures one hour. Glycerol, a co-product of
(processing steps). Seven flow sheets the acylglycerol transesterification,
where created to optimize input and separates from the oil phase as the
production cost by managing jatropha reaction proceeds. The reaction
oil and methanol consumption ,and extent is approximately 90%. The
environment impact . material is then fed to a centrifugal
The reaction section is the same for separator (DC-101) where the
all process variation. The differences biodiesel and the unreacted Jatropha
will be outlined bellow in each case. oil are separated from the glycerol-
rich co-product phase. The latter, is
sent to the glycerol recovery unit.

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Biodiesel Refining Section to yield an 80% pure glycerol which


This section consists of : is then sold to industrial glycerol
• Two continuous centrifugal refiners at a price of $0.33/kg.
separators ( DC-102 ) Both glycerol streams (S-109) and
• A mixing vessel (V-103) fatty acid contaminants (S-112)
The crude biodiesel stream is washed exiting the reactors are pooled and
with acidified water at a pH of 4.5 in a treated with acid (HCL) in (V-102)
mixing tank (V-103) to neutralize the to convert soaps into free fatty acids
catalyst and turn any soaps into free which are subsequently removed by
fatty acids. The material is then fed centrifugation (DC-103). The fatty
to a continuous centrifugal separator acid stream is destined to disposal.
(DC-102) to separate the biodiesel The glycerol stream is then neutralized
from the aqueous phase, which is with caustic soda in (V-104). The
fed to the glycerol recovery section. methanol contained in the glycerol
The biodiesel product stream must stream is recovered by distillation
not contain more than 0.050% w/w (C-102). Finally the glycerol stream
water. is concentrated to reach 80% purity
Glycerol Purification Section by another distillation step (C-101)
This section consists of: that removes the water.
• Two mixing vessels (V-102 & Two Reactors System
V-104) Reaction section
• A centrifugal separator (DC-103) The reaction section consists of :
• Two distillation columns (C-101 & • The two reactors (V-104 and V-105)
C-102) • A decanter centrifugal separator
Glycerol produced during trans- (DC-101)
esterification requires purification The jatropha oil is directly fed to the
before it can be sold. The equipment reactor (V-104). Methanol and the
is sized to remove methanol, the catalyst are mixed and 90% of the
fatty acids, and most of the product mixture is fed to the first reactor. The

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rest (10%) is fed to the second reactor. efficiency of 99%.


According to the reaction mentioned Again the mixture of methyl esters
before, methanol reacts with jatropha (biodiesel), glycerol, un reacted
oil and yields biodiesel and glycerol. substrates and catalyst exiting the
Product is removed at a rate equal second reactor is fed to another
to the rate of charging the reactants centrifugal separator (DC-102).
and catalyst. The average residence Biodiesel Refining Section
time of materials in the reaction is The same as in one reactor.
1 h. Glycerol, a co-product of the Glycerol Purification Section
acylglycerol transesterification, The same as in one reactor design but
separates from the oil phase as the here there is no need for distillation
reaction proceeds. The reaction to remove methanol and water .
extent is approximately 90%. Then The equipment is sized to remove
fed to a centrifugal separator (DC- methanol, the fatty acids, and most of the
101) where the biodiesel and the product to yield an 99% pure glycerol .
jatropha oil that has not reacted are Oil Recovery System
separated from the glycerol-rich co- The recovery of the unused Jatropha
product phase. The latter, is sent to oil saves input costs for the process
the glycerol recovery unit. , and make the process environment
The biodiesel stream, which also friendly by reducing organic waste.
contains unreacted methanol, In glycerol purification section
jatropha oil and catalyst is fed into the decanting separator (DC-103)
a second stirred tank reactor (V- is optimized to remove un reacted
105) along with the addition of the Jatropha oil and recycled it to the
methanol-catalyst stream from the first reactor(V-101), and glycerol
splitter (FSP-101). The reaction purity reached 93%.
conditions are the same. The reaction Methanol Recovery System
extend in the second reactor is 90% Methanol recycle is necessary
which yields a combined conversion because an excess of methanol

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is required for an effective recovered by distillation (C-102)


transesterification reaction system. and recycled back to the first reactor
The recovery of the unused methanol (V-101). Finally the glycerol stream
saves input costs for the process and is concentrated to reach 93% purity
essentially eliminates the emissions by another distillation step (C-101)
of methanol to the surroundings. which removes water .
The emissions reduction is needed One Reactor with Two Reactions
because methanol is highly System
flammable and is toxic. In the reaction section where
In glycerol purification section the another transesterfication reaction
methanol contained in the glycerol occurs in the stirred tank reactor (V-
stream is recovered by distillation 103) which is used to wash crude
(C-102) and recycled back to the first biodiesel with acidified water at a
reactor (V-101). Finally the glycerol pH of 4.5 to neutralize the catalyst
stream is concentrated to reach 92% and turn any soaps into free fatty
purity by another distillation step (C- acids.The reaction conditions are
101) that removes the water. the same. The reaction extent in the
Oil and Methanol Recovery second reactor is 90% which yields
System a combined conversion efficiency
The recovery of the unused oil and of 99% .Finally the glycerol stream
methanol is very important because is concentrated to reach 95% purity
it saves input costs for the process by another distillation step (C-101)
and perform clean production. which removes water.
In glycerol purification section the Two Reactions and Methanol
decanting separator (DC-103) is Recovery System
optimized to remove unreacted The design is the same as the one
Jatropha oil and recycle it to the reactor with two reactions system but
first reactor(V-101),The methanol differs in the glycerol purification
contained in the glycerol stream is section where the methanol

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contained in the glycerol stream is recycling of crude Jatropha oil and


recovered by distillation (C-102) methanol proved cost effective
and recycled back to the first reactor because of reduction in input costs
(V-101). Finally the glycerol stream and are environmentally friendly
is concentrated to reach 96% purity .Refer to tables ( ‎2and 3),and figures
by another distillation step (C-101) (3,4, 5, 6, 7, 8, 9, 10, 11,and 12)
which removes water. below .
Results and Discussion Table 2: Break even point

Analysis and review of the results


showed that plant designs involving

PR OC and TR
Design case
(kg MP/yr) ($/yr)

One reactor 45,420,000 33,140,000

Two reactors 38,370,000 28,020,000

Oil recovery 33,210,000 24,340,000

One reactor -two reactions 32,880,000 24,100,000

Methanol recovery 40,570,000 29,600,000

Oil and methanol recovery 30,730,000 22,530,000

Two reactions and


30,460,000 22,320,000
methanol recovery

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Figure 3: Production rate vs OC and TR

Table 2 above ,shows that oil crude Jatropha oil and methanol with
and methanol recovery ,and two reduce input cost.For production rate
reactions and methanol recovery (PR) more than what mentioned the
designs are preferable because they project is profitable.
become profitable with lowest Sample figure 3above ,shows the
production rate and operating cost breakeven point for oil and methanol
due to consuming or recycling of recovery design.

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Figure 4: Effect of scale-up on Production rate (kg MP/yr)

Figure 4 , shows that high production reactions and methanol recovery


rates achieved by oil recovery ,oil designs.
and methanol recovery ,and two

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Figure 5: Effect of scale-up on Total capital investment ($)

Figure 5,shows that the minimum methanol recovery and two reactions
total capital investment requirments and methanol recovery designs

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Figure 6: Effect of scale-up on Operating cost

The minumum operating cost acived ,because of reducing input cost by


by methanol recovery ,oil and either consuming or recycling crude
methanol recovery,and two reactions Jatropha oil or methanol. As shown
and methanol recovery designs in Figure 6.

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Figure 7: Effect of scale-up on Total revenues

As shown in Figure 7,the highest total reactions and methanol recovery


revenues achieved by oil recovery, designs, because of reducing input
one reactor with two reactions ,oil cost by consuming or recycling
and methanol recovery ,and two crude Jatropha oil.

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Table 3: NPV
Design PR(kg MP/yr)

one reactor 50900000

two reactors 43220000

oil recovery 36940000

one reactor two reactions 36570000

methanol recovery 45380000

oil and methanol recovery 34190000

two reactions and methanol recovery 33900000

Table 3,shows production rate at designs with consuming or recycling


witch present value is equal to zero , of crude Jatropha oil and methanol
so for production rate more than what show low rates of production to be
is mentioned the project is profitable . profitable.

Figure8: Effect of scale-up on NPV

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Figure 8,shows that desings with and methanol recovery designs) had
consuming or recycling crude the highest NPV values so they are
jatropha oil and methanol (two preferable.
reactions and methanol recovery,oil

Figure 9: Effect of scale-up on Return on investment

As shown in figure 9, the highest designs, because of reducing input


return on investment percentage were cost by consuming or recycling both
obtained at all production rates by of crude Jatropha oil and methanol.
two reactions and methanol recovery
and oil and methanol recovery

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Figure 10: Effect of scale-up on Payback time (yr)

Figure 10,shows that for high money subjected to the project so


production rates all design cases these designs (oil recovery, one
are acceptable ,but in lowest scale reactor with two reactions ,two
designs with consuming or recycling reactions and methanol recovery
crude Jatropha oil the main input ,and oil and methanol recovery) are
material show less time to restore preferable .

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Figure 11: Effect of scale-up on IRR (%)

As shown in figure 11, the highest methanol recovery designs ,because


internal rate of return percentage of reducing input cost by consuming
achieved by two reactions and or recycling both of crude Jatropha
methanol recovery and oil and oil and methanol.

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Figure 12. Fuel Product Consumption in Sudan, 2012,


(Thousands of metric tons),[6]

Figure 12,shows that diesel consumed in 2012 is about 2998000 ton or


2998000000 kg

The highest production rate (more than 11%) 338,220.83450 ton or


338220834.50 kg .

This mean that by implementing this project in port diesel will decries by
about 11% .

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Figure 13: Effect of scale-up on Unit production cost ($/kg MP)

Figure 13, shows that Jatropha biodiesel price is compatible with diesel fuel
world price of about 800 $/ton to 1200 $/ton, while Jatropha biodiesel unit
production cost is about 520 to 1040 $/ton depending on the production
rate.

Biodiesel produced can be used by blending it with diesel by 5 % , 10% ,


20 % , and 50 % .Recent research shows that motor engines can work with
B50 without modifications [7] .

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Conclusions is compatible with diesel fuel world


The capital investment for a 15000 price of about 800 $/ton to 1200 $/
and 300000 MT/year plants is around ton ,while Jatropha biodiesel unit
27 to 65 $ million respectively. The production cost is about 520 to 1040
annual operating cost is around $/ton depending on production rate.
15.761 to 181.825 $ million and Plant designs involving recycling
that translates to a unit production of crude Jatropha oil and methanol
cost of around 0.6 to 1.04 $/kg. proved cost effective and
with revenues of around 11.108 to environmentally friendly .
222.168 $million/year. The Payback At a production rate 300000 MT/
period of 11.8 to 1.72 years. year Sudan diesel imports will be
One of the most important findings reduced by 11%.
of this study is that biodiesel price

References
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[2] Hazir Farouk Abdelraheem , Andrew Lang ,and Mohammed Elhadi
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[4] Lars Kåre Grimsby, Jens Bernt Aune ,and Fred Håkon Johnsen
, Human energy requirements in Jatropha oil production for rural
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297-302,Elsevier,(2012).
[5] Joshua Folaranmi, Production of Biodiesel (B100) from Jatropha Oil Using
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Group,(2009) .

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Nomenclatures
BEP : Break Even Point
B1 % - B99 % : Biodiesel Blend Percentage in Gallon of fuel
CJO : Crude Jatropha Oil
FFA : Free Fatty Acid
HC : Hydro Carbon
IRR : Internal Rate of Return
J : Jatropha
JME : Jatropha Methyl Esters
MATLAB : Matrix Laboratory
MFP : Multi Functional Platform
MP : Main Product
MT : Metric Ton
NPV : Net Present Value
OC : Operating Cost
PR : Production Rate
TR : Total Revenues
VOC : Volatile Organic Component

142

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