CHAPTER 1

ABSTRACT

This study was primarily focused in Fabrication and Testing of Biodiesel Prototype.

The study aims in the kinetic reaction of second-used cooking oil transesterification into
biodiesel and find the optimum condition of its process. This research was done by
transesterification reaction in batch reactor. The feedstock was collected from the street sellers
and restaurant in San Fernado Pampanga.

Methanol was used as a reactant and KOH was used as a base catalyst. The study parameters
were temperature, alcohol to oil molar ratio, and catalyst concentration. Several types of analysis
used were free glycerol analysis, total glycerol analysis, free fatty acid (FFA) analysis, and
saponification analysis. These analyses were used to calculate the yield of conversion and ester
content of biodiesel sample. From this research, it is found that the kinetic reaction of second-
used cooking oil transesterification can be expressed by k = 0.0251exp (-15.29/RT)
dm3/(mol.min). The optimum condition (the ester content 92.76%) of biodiesel production were
obtained at temperature 66.5oC, molar ratio of methanol to oil 6.18:1, and 1 wt.% KOH.

The Biodiesel Prototype was able to produce 18 liters of biodiesel from 25 liters of used cooking
oil.

Overall, the Biodiesel Prototype worked well and functioned according to its intended used and
purpose of development.
INTRODUCTION

The basic concept of biodiesel synthesis was invented by Rudolf Diesel in the 1890s, and the
diesel engine had become the device of choice for power reliability and high fuel economy
globally. He envisaged that pure vegetable oil could be used on compression ignition engine as
fuel. 

The energy consumption has increased every year in line with the increase in human
population. This increase occurred in various sectors including transportation, power generation,
industry and households. Until now, the world's energy needs are supplied by fossil fuels. By
2030, it is estimated that the increase in energy consumption reaches 53%, so that the oil reserves
expected to be exhausted within the next 41-63 years. The use of fossil fuels continuously,
causing environmental impacts such as the increase of CO2 emissions that result in accelerated
of global warming, air pollution and other environmental issues. The rapid depletion of fossil
fuels and the increasing energy needs has encouraged each country to make savings and
conducting various studies to obtain renewable fuels.

Biodiesel and its blends with diesel fuel are investigated to solve the problem of
depletion of fossil fuels and environmental impact.Biodiesel came into effect in 1990’s due
to global warming, greenhouse gas emission from vehicles and its benefits over normal diesel
such us non sulfur emissions, low toxicity ,biodegradable and ecofriendly. Biodiesel is obtained
from renewable sources like fresh or used vegetable oils, animal fats etc. Biodiesel as an
alternative fuel for diesel fuel, is methyl or ethyl esters extracted by transesterification
process It is superior to diesel fuels in terms of Cetane number, flashpoint, lubricity, exhaust
emissions. It can be blended with conventional diesel in some proportions can be used to run any
existing conventional CI engine and does not require any engine modifications.
BACKGROUND OF THE STUDY
Waste cooking oil

When not disposed properly, waste cooking oil is not good for the environment. It can
cause serious damage to local water supply and also, can be problematic for wildlife. Dumping
waste cooking oil can also cause damage to your sewer and septic systems, and cause a great
deal of repair to have to be made costly repair. Dumped cooking oil actually causes a large
number of issues with sewer and septic systems because as used oil cools and settles it congeals,
which can clog up pipes and cause corrosion of certain materials.

Over used
cooking oil
Another research says that reusing oil creates free radicals, a type of molecule, that attach
themselves to healthy cells and may cause health diseases, including cancer. Consuming food
prepared using reused oil over long periods also has a risk of causing acidity, heart disease,
Alzheimer’s and Parkinson’s disease, and irritable throat. Specifically, a recent study has shown
that thermally-abused or reheated cooking oil possibly triggers cell changes that can promote
late-stage breast cancer growth. Waste cooking oil can be used as source to produce biodiesel.
It has environmental and economic advantages over other alternative fuels.

Biodiesel and its history

The idea of using alternative fuels is not new in its nature; it has existed in the past for many
years. Alternative diesel engine fuels that have been researched over the years range from coal
to peanut oil. During the 1900 Paris World Fair, the French Otto
Company ran the Diesel Engine on peanut oil at the request of the French government. A
Belgian patent granted in 1937 to G. Chavanne displays the early existence of the use of ethyl
esters extracted from palm oil (Knothe et al., 1997). But the inexpensive petroleum-based fuels
prevented biodiesel fuels from receiving much consideration, resulting in adoption of a diesel
engine to specifically burn petroleum diesel. Interruption of cheap oil supplies resulting from
the 1973 oil embargo as well as the 1990 Gulf War sparked a renewed interest and research in
using domestically grown and renewable sources for fuel production. Although the use of
biodiesel did not receive much attention in the United States until the late 1990s, it has been
used extensively in Europe for nearly a quarter of a century. It is important to understand how
a diesel engine functions in order to understand the necessary characteristics of biodiesel and
why biodiesel is a suitable alternative fuel for petrodiesel.

PetroDiesel
Petrodiesel is processed from crude oil, a fossil fuel with broad variations in color, from clear to
tar-black, and viscosity, from that of water to almost a solid. Crude oil contains a complex
mixture of hydrocarbons comprised of differing chain lengths and physical and chemical
properties. The hydrocarbons can be divided into 5 total groupings consisting of three
predominant groups (paraffins, aromatics, and naphthenes) and 2 minor groups (alkenes,
dienes and alkynes) as shown in Table (2.2) (OTM, 1999). Crude oils are composed of 80 to 90%
hydrogen saturated aliphatic alkanes (paraffins) and cycloalkanes (naphthenes). Aromatic
hydrocarbons and alkenes (olefins) comprise 10-20% and 1%, respectively, of crude oil
composition (ATSDR, 1995). Hydrocarbons containing up to four carbon atoms are gaseous in
nature, those with 5 to 19 carbon atoms are usually found in liquid form, and those with a
carbon composition greater than 19 are found as solids.

Operation of Diesel Engine

As opposed to a typical engine, a diesel engine does not employ spark plugs. Therefore,
extreme temperature and pressure is required to ignite the fuel. Diesel engines utilize internal
combustion. In this process, burning of a fuel occurs in a confined space called a combustion
chamber. When the gas is compressed, the pressure rises, affecting a resultant increase in
temperature. In a diesel engine, air is drawn into a cylinder and compressed by a rising piston at
a much higher compression ratio (25:1) than for spark ignition engine. The air temperature
reaches 700ºC to 900ºC. At the top of the piston stroke, the diesel fuel is injected into the
combustion chamber at high pressure via an atomizing nozzle, mixing with hot, high-pressured
air. The resulting mixture ignites and
burns very rapidly. This contained combustion causes the gas in the chamber to heat up rapidly,
resulting in an increase in pressure, thereby forcing the piston downwards. The piston is
connected to rods through which it delivers rotary power at the output end of the crankshaft.
This engine system is known as a Direct Injection system (DI). A DI system utilizes diesel since
diesel oil has a much lower flash point than gasoline (Billen et al., 2004). Another type of engine
is the Indirect Injection Diesel (IID) engine in which fuel is preheated in a different chamber
prior to contact with the hot air. Injection takes place at a lower pressure and the spraying
holes are larger than those in a DI system (Billen et al., 2004). Modern diesel engines are
typically of the DI type.
Petrodiesel is processed from crude oil, a fossil fuel with broad variations in color, from clear to
tar-black, and viscosity, from that of water to almost a solid. Crude oil contains a complex
mixture of hydrocarbons comprised of differing chain lengths and physical and chemical
properties. The hydrocarbons can be divided into 5 total groupings consisting of three
predominant groups (paraffins, aromatics, and naphthenes) and 2 minor groups (alkenes,
dienes and alkynes) as shown in Table (2.2) (OTM, 1999). Crude oils are composed of 80 to 90%
hydrogen saturated aliphatic alkanes (paraffins) and cycloalkanes (naphthenes). Aromatic
hydrocarbons and alkenes (olefins) comprise 10
20% and 1%, respectively, of crude oil composition (ATSDR, 1995). Hydrocarbons containing up
to four carbon atoms are gaseous in nature, those with 5 to 19 carbon atoms are usually found
in liquid form, and those with a carbon composition greater than 19 are found as solids.

Biodiesel and glycerin separation

Transesterification of natural glycerides with methanol to methylesters is a technically

important reaction that has been used extensively in the soap and detergent manufacturing
industry worldwide for many years. Almost all biodiesel is produced in a similar chemical
process using base catalyzed transesterification as it is the most economical process, requiring
only low temperatures and pressures while producing a 98% conversion yield. The
transesterification process is the reaction of a triglyceride (fat/oil) with an alcohol to form esters
and glycerol. A triglyceride has a glycerin molecule as its base with three long chain fatty acids
attached. The characteristics of the fat are determined by the nature of the fatty acids attached to
the glycerin. The nature of the fatty acids can, in turn, affect the characteristics of the biodiesel.
During the esterification process, the triglyceride is reacted with alcohol in the presence of a
catalyst, usually a strong alkaline like sodium hydroxide. The alcohol reacts with the fatty acids
to form the mono-alkyl ester, or biodiesel, and crude glycerol. In most production, methanol or
ethanol is the alcohol used (methanol produces methyl esters, ethanol produces ethyl esters) and
is base catalyzed by either potassium or sodium hydroxide. Potassium hydroxide has been found
more suitable for the ethyl ester biodiesel production, but either base can be used for methyl ester
production.

Chemical changes take place during frying of vegetable oil. Waste cooking oil contains free fatty
acids and moisture content which have the ability to form soaps. Pre-treatment of waste cooking
oil is necessary in order to prevent soap formation. The treatment consists of mechanical
cleaning with water and chemical cleaning for removal of resins and deacidification.

One of the great advantages of biodiesel is that it can be used in existing engines, vehicles and
infrastructure with practically no changes. Biodiesel can be pumped, stored and burned just like
petroleum diesel fuel, and can be used pure, or in blends with petroleum diesel fuel in any
proportion. Many alternative fuels have difficulty gaining acceptance because they do not
provide similar performance to their petroleum counterparts. Pure biodiesel and biodiesel
blended with petroleum diesel fuel provide very similar horsepower, torque, and fuel mileage
compared to petroleum diesel fuel. In its pure form, typical biodiesel will have an energy content
5%-10% lower than typical petroleum diesel.

STATEMENT OF THE PROBLEM

 The main purpose of this study is to fabricate a prototype that can convert waste cooking
oil into biodiesel that serve as the solution for the following problems that stated below.

1. The limited dumping site for the waste cooking oil.

2. The high cost of other company on treating waste cooking oil.
3. The health risk that can obtain by recycling and reusing used oil.
4. The high carbon emission produced by petroleum products.

OBJECTIVES OF THE STUDY

General Objectives

The study aims the fabrication of a prototype that can treat and convert the used cooking oil
into a biodiesel that intended to achieve the specific objectives listed below.

1. To produce 74% output which equivalent to 18 liters of biodiesel from 25 liters of used
cooking oil.
2. To eliminate the use of pump by depending on the force of gravity that can be obtain by
constructing at a vertical position
3. To produce a biodiesel that has a torque of 25kn.M
4. To separate the glycerin and the methanol through the help of heat exchanger.
Conceptual Framework
SCOPE AND DELIMITATIONS

1. The study will focus only fabrication and testing of the prototype reactor, filter and

the

integrated heat exchangers, hence the evaluation of the prototype's overall performance

is far off the study.

2. The series of tests to be conducted throughout the study will be focused only in the

characterization of biodiesel. Therefore, the evaluation of biodiesel quality for different

temperature ranges is not covered.

3. The focus of the research is only the treatment and conversion of used cooking oil, so

the quality of biodiesel depending on how many times it is reused is beyond the scope of

study.

4. The further use of glycerin is beyond the range of the study because our research is

only focused in the separation of biodiesel and glycerin.

SIGNIFICANCE OF THE STUDY

The study is designed to provide solutions to the need of finding new source of energy or fuel. It
will provide technical datas that are useful to further studies and references.This in turn will be
beneficial for groups of people including but not limited to:

1. The Environment
In cases that waste oils which have not any treatment first, will pollute the environment. One of
the ways to treat the waste oil is by converting to biodiesel. This research aimed to study the
kinetic reaction of second-used cooking oil transesterification into biodiesel and find the
optimum condition of its process.

2. Health
Reusing this deep fried oil repeatedly for frying purposes is responsible for many health hazards
in human population. Increased viscosity and darkening in color are some of the physical
changes which can alter the fatty acid composition of the cooking oil on repeated frying.
Oxidation, hydrolysis and thermal polymerization are the chemical reactions occurring as a result
of repeated heating of cooking oil for low and cheap food production.

3. The Researchers
The researchers, especially those that are finding new alternative fuel to use other than the
common renewable ones might use the study to be one of their reference materials as they
conduct their own study related to biodiesels.

4. The Scientific and Engineering Community

The study employs established and innovative technologies derived from the engineering
theories and design; digging up the classic ideas and technologies to answer today’s problems.
Hopefully, this “renaissance of lost technologies” will contribute and be recognized by the
scientific and engineering communities in the country.
CHAPTER 2

REVIEW OF RELATED LITERATURE AND STUDIES

2.1. Introduction

This literature review used various academic articles related to topics on the recycling of used
cooking oil to produce biodiesel and green economy. The review outlined the importance of
green economy; advantages and disadvantages of biodiesel; environmental management;
challenges facing small scale biodiesel producers; and lessons from other countries.

The theories on green economy as an influential part to the recycling of used cooking oil to
produce biodiesel was guided by various literatures relative to the topic of the research.
2.2. Theoretical framework

The process for making biodiesel is summarized as follows:

 Preheat used vegetable oil to remove water

 Determine oil pH and measure appropriate quantity of NaOH and methanol - Mix
reactants
 Allow glycerin to settle out, drain glycerin and send to methanol recapture
 Wash biodiesel to remove trace contaminants
 Set in the sun to drive off traces of water

The theory on green economy focuses on knowledge of climate change, greenhouse gas
emissions, waste management, renewable fuel and energy, and economic growth. Various
scholars agree that climate change has become a global problem which can be addressed through
the use of renewable fuels in order to reduce environmental risks posed by greenhouse gas
emissions.

Since it is widely regarded as an environmental friendly fuel, Biodiesel is regarded as one of the
solutions to reduce greenhouse gas emissions and has significant economic benefits for overall
biodiesel production value chain.
The green economy theory further focuses on turning waste into valuable resources. Used
cooking oil has always been considered a waste and an environmental problem, but is now
considered a useful resource if recycled into biodiesel. Recycling has become an important
alternative of waste management, through its ability to minimize environmental health risks; and
for socio economic benefits through job creation, poverty reduction and reduction in social
inequality.

2.3. Research Literature

Biodiesel is defined as a renewable environmental friendly fuel that has the potential to
supplement the use of petroleum diesel fuel. Biodiesel is regarded as a sub-sector of green
economy which can contribute towards reducing carbon emission as claimed by its proponents.

The recycling of used cooking oil has been identified as an alternative resource for biodiesel
production. A shift from petroleum diesel to a biodiesel fuel has the potential to benefits both the
environment and socio economic issues to achieve green economy goals through job creation;
poverty alleviation; and improved social equity.

2.3.1. Transesterification

Vegetable oil is pre-treated with catalyst to form esters of free fatty acids (FFA) in order to
eliminate saponification reaction. The reaction useful when raw material contains high content of
FFA.
2.3.1.1. Water content

Water content in waste cooking oil reduces the amount of ester formation and accelerates the
hydrolysis process. Water content should be less than 0.5% to attain 90% biodiesel and it is more
critical for acid catalyzed reaction than base catalyzed reaction. Water is obtained as by-product
when acid catalysts are used for esterification of FFA to form esters. Presence of water in
biodiesel decreases efficiency of engine. Waste cooking oil can be heated up to 120°C to
evaporate water and water vapors can be removed by anhydrous sodium sulphate or anhydrous
magnesium sulphate. Presence of certain amount of water is required for some enzymes to be
activated.

2.3.1.2. Type of alcohol

Methanol is used for biodiesel production in most of the cases as its recovery is easier from final
product. Biodiesel yield from waste cooking oil is much higher by using methanol than other
alcohols. Viscosity of biodiesel obtained is also lower by using methanol. Methanol is less costly
but more toxic tan ethanol. Azeotrope and water are formed when ethanol is used, making the
separation of alcohol from water difficult during distillation. Some cases involve addition of i-
butanol or t-butanol as solvent to avoid the inhibition of lipase by glycerol or methanol.

2.3.1.3. Catalyst type

Researchers have used various catalysts for the production of alkyl esters. It can be concluded
that fastest catalyst is NaOH and among the catalysts used. Raw materials with higher FFA
content, aid catalysts are used for transesterification. The problems related to the usage of
homogeneous catalysts are soap formation and recovery of catalyst from final product. Research
has shown that heterogeneous catalyst is not affected by FFA and moisture present in raw
material. Enzyme catalytic reaction is slower than other catalytic reactions used for
transesterification. The separation is easier for enzyme catalysts but preparation of enzyme
catalyst is critical.

2.3.1.4. Alcohol to oil ratio

Three moles of alcohol and one mole of triglyceride are needed to produce three moles of alkyl
esters. Alcohol to oil ratio has positive effect on production of biofuel. Product formation rate
increases as the concentration of reactant increases. Increase in molar ratio of alcohol to oil
increases the product formation.

2.3.1.5. Free fatty acid (FFA)

Waste cooking oil has higher content of FFA than fresh cooking oil. Higher FFA content will
lead to formation of water and soap. Transesterification process will not proceed if FFA content
exceeds 3% even with homogeneous base catalyst. The problem can be solved by using
heterogeneous catalyst or by pre-treatment with homogeneous or heterogeneous acid catalyst for
esterification of FFA to form free fatty acid esters. Rate of acid catalyzed reaction is low and
soaps formed during neutralization of FFA by using base catalyst can be converted into FFA by
adding phosphoric acid.

2.3.1.6. Temperature

There is significant effect of temperature on transesterification. Increase in temperature increases

biodiesel yield and reaction rate. Temperature shouldn’t exceed the boiling point of alcohol to
avoid evaporation of alcohol. Viscosity of biodiesel will increase if temperature is maintained
below 50°C. Waste cooking oil is heated up to 120°C in order to remove water and then cooled
up to 60°C. Highest biodiesel yield was recorded at 65°C for waste cooking oil by using KOH
catalyst.

2.3.1.7. Reaction time

Reaction time depends upon the availability of reactants and 99% of yield can be obtained if
reaction is carried out for longer period. Reaction time has an impact on the properties of
biodiesel. The reaction time should be optimized in order to maximize yield and minimize the
production cost.

2.3.1.8. pH

It isn’t the major factor while using acid or base catalyst but it can be considered during the
usage of lipase as catalyst because enzyme can be decomposed at lower or higher pH values.

2.3.1.9. Stirrer speed

Proper mixing of reactants is necessary for completion of transesterification reaction. Agitation

increases the rate of reaction as well as diffusion of reactants and catalyst into each other.
Optimizing the stirrer speed is necessary to obtain maximum yield.
2.3.1.10. Catalyst concentration

High temperature conditions are required for the conversion of waste cooking oil into renewable
fuel without using catalyst. Biodiesel yield increases with the increase in concentration of
catalyst. However, conversion rate decreases with the increase in catalyst concentration maybe
due to increase in viscosity of mixture. Optimum concentration of catalyst may vary with type of
raw materials and catalysts

2.3.2. Advantages of Biodiesel

Biodiesel emit less carbon monoxide and has great environmental advantages than petroleum
diesel. Biodiesel production is economically effective as its production process generates
glycerol (by-products), which is useful in the manufacturing of glycerin and soap. In this case
profits could be made in downstream biodiesel production value chains.

The most important advantage of vegetable oils, is that they are renewable and sustainable
compared to petroleum oil which is said to be depleting with time. The recycling of used cooking
oil as a resource for biodiesel production also add to the advantages of biodiesel; as this may also
help to reduce illegal dumping of used cooking oil, in the municipal sewage drainage systems,
and to address environmental degradation.

Generally, most researchers conclude that biodiesel production from used cooking oil is
inexpensive; economically effective; and safe to the environment and public health.
2.3.3. Disadvantages of Biodiesel

Very few disadvantages have been identified in literature. Some authors argue that the cost of
biodiesel is likely to increase in future due to expected demand and lack of vegetable oil during
drought years/seasons in the long run. Furthermore, production costs may also cause supply
challenges.

The most common disadvantage of biodiesel has been its adaptability in cold weather, as this
may affect its combustion level and reduce engine power. However, given the fact that
Philippines is located in the warmer region, this disadvantage is less likely to discourage
production of biodiesel in Philippines.

FOREIGN STUDIES

Renewable resources of biodiesel production in foreign countries

The recycling of used cooking oil to produce biodiesel is currently growing in foreign countries.

The United States is regarded as the world leader in biodiesel production (Zhang H. , Ozturk,
Wang, & Zhao, 2014).
There have been a number of studies conducted to determine the quantity of WCO produced per
year nationally or per restaurant. In 1998 the US Department of Energy’s National Renewable
Energy Laboratories (NREL) conducted a waste grease resource study of 30 metropolitan cities
in the US. This study indicated little variability between the number of restaurants per 1000
people in urban areas with a range of 1 to 2 restaurants/1000 people and a weighted average of
1.41. The NREL study also concluded that each restaurant produces a weighted average range of
6,268 - 9,453 pounds (3250 – 4875 liters) of WCO per year (Wiltsee, 1998). Based on these
numbers the national production of WCO with a population of 295 million is between 2.61 –
3.94 billion gallons a year. This is equivalent to 6.1 – 9.2% of the total US diesel use for the
transportation sector in 2004 (Energy Information Agency, 2005). This study concluded that
between the years of 1995 and 2001 the average production of WCO was 2.63 billion gallons
(Groschen, 2002).

The amount of cooking oil consumed in Japan in for year 2008 came to 2.27 million tons, of
which 1.9 million tons was consumed by the food service industry / food manufacturing industry
and 370,000 tons was consumed by ordinary households.

Conversely, 330,000 - 350,000 tons and 90,000 - 110,000 tons of waste cooking oil are
simultaneously generated by the food service industry / food manufacturing industry and
ordinary households, respectively. Of this, as much as 60,000 - 80,000 tons of waste cooking oil
from the food service industry / food manufacturing industry and 90,000 - 100,000 tons from
ordinary households go unused.

The amount of biodiesel fuel produced from waste cooking oil has been steadily increasing from
4,471kℓ (FY2006), to 6,229kℓ (FY2007), 6,949kℓ (FY2008), and 8,568kℓ (FY2009).

Conversely, the manufacturing costs have been dropping from year to year; from 104 yen/ℓ
(FY2006, though this was 135 yen/ℓ in local municipalities), to 124 yen/ℓ (FY2007), 117.6 yen/ℓ
(FY2008), and 99.8 yen/ℓ (FY2009).

In Padang Indonesia it is estimated that the highest amounts of WCO come from medium, low,
and high income households, respectively. This is most likely due to the population number of
those sources. Based on the figure, approximately 26,060.79 and 8,484.09 litres/week of WCO
are generated.

Waste Management and Environment Health in Foreign Countries

Japan and the USA, have made huge progress in recycling used cooking oil for biodiesel
production, and are more advanced in the treatment and implementation of environmental waste
management policies that deal specifically with disposal of used cooking oil.
Japan has enacted the food waste recycling law, which makes recycling an obligation for
catering companies as a means of reducing waste generation; and also provides subsidies and tax
incentives to encourage recycling of used cooking oil.
The USA has strict regulation and legislations to deal with waste management and pollution;
there are subsidies to encourage production and use of biodiesel; and heavy fines are issued to
violators of regulations (Zhang, Wang, & Mortimer, 2012).

In China, the disposal of used cooking oil has been standardized for collection, transportation
and disposal by municipalities; and some related sector departments have rules and regulations to
manage of used cooking oil (Zhang, Wang, & Mortimer, 2012).

Most households in Padang, Indonesia (up to 73-80%) are willing to participate in collecting the
waste, although some of them (57-68%) required the waste containers to be provided by other
parties. As for the food sellers, around 48-76% will join to collect the wastes, but most of them
(42-68%) have some conditions that must be fulfilled, e.g., institutions that want to utilize the
waste must pay money for their participations. On the other hand, 13-16% household
respondents are against the proposed plan, while the number is higher for the food seller
respondents (up to 43%). Hesitant respondents for households and food sellers are 5-13% and 4-
12%, respectively.

South Africa for instance, is currently developing a carbon tax policy with the aim of regulating
carbon emissions. However, the regulation of used cooking oil seems to be lacking in most local
municipalities (Nhamo, 2014). Scholars, argue that government is key and plays a major role in
promoting production of renewable fuel to ensure environmental sustainability through biodiesel
production from recycled used cooking oil.

Most households in Padang, Indonesia (61-75%) directly discharged the waste into the sewer,
while the figure is 24-43% for the food sellers. Although at present there is no regulation that
bans this waste handling practice in Padang Municipality, however this activity is not acceptable
due to the risk of water pollution issues.

Most household respondents in Padang, Indonesia (51.26%) re-used the cooking oil up to 3
times. On the other hand, almost all food sellers re-used the cooking oil more than once. Around
16% of street food vendors re-use the cooking oil more than 8 times. Re-using cooking oil has
been studied by many researchers with a similar conclusion, i.e., it causes health problems due to
the formation of free radicals during the re-heating of the cooking oil.
Key successes of recycling used cooking oil to produce biodiesel

The success of countries like the USA and Japan in recycling used cooking oil to produce
biodiesel have been influenced mainly by the role government plays through policies, waste
disposal regulations, and collection fees (Zhang H., Ozturk, Wang, & Zhao, 2014). Japan has
successfully reduced the reuse of used cooking oil for consumption in the catering industry
through the adoption of a hygiene licence system, and strict daily supervision and risk
management systems (Zhang, Wang, & Mortimer, 2012).

CHAPTER 3

METHODOLOGY

This chapter outlines the research strategy, methods and procedures to achieve the
objectives of the study. It was started with the discussion of the project design and development.
Then, the prototype concepts and design improvements are presented. The chapter also describes
the research techniques to gather and analyze the informations needed. The testing procedures
for the prototype performance and evalutaion of biodiesel quality are also presented. The chapter
ends with the discussions in the instruments and techniques used.

3.1 Project/Research Design

 The project/research design is used to discuss the methods, procedures and techniques
used in collecting and analyzing the desired data.

The study started with the surveys conducted in the restaurants around City of San
Fernando area. Jollibee, McDonald's and ChowKing were interviewed to gather datas needed for
the research. Ocular visits were done in the chicharon stalls along the highway of Betis, Guagua
for further informations. The frequently asked questions during the interviews were about the
average volume of used oil left after cooking and the place of disposal. After surveys, literatures
and related studies about the conversion of used cooking oil to biodiesel were done.

3.2 Project Development

After those activities, the preliminary design of the prototype was started using the
concepts and ideas collected from the previous chapters. It was done through rough sketches and
specification of parts and materials. Based on the initial information gathered, it was decided to
improve the prototype design into a gravitational flow design.
 After the preliminary design, comes a yes-no question “is the design feasible?”. The
criteria are: materials availability and fabrication shop capability. No-answer means going back
to the preliminary design phase; and yes-answer means proceeding in the design using the

Figure 3-1. Project Design and Development Diagram

preferred CAD software; fabrication of the working drawings; materials and manufacturing
processes selection, and ultimately, the fabrication of the prototype.

3.2.1 Preliminary Design of Heat Exchangers, Filter and Reactor

The prototype is composed of four cylindrical tanks. The three tanks are the heat
exchangers: the pre-heater, condenser and evaporator, and the other tank is the reactor. The used
cooking oil is pumped into the pre heater which uses electric coil placed at the bottom for
heating. Pre heating is important to reduce the viscosity of oil for faster gravitational flow. The
pre heated oil is fed to the filter with removable filtering net using a gate valve. After filtering,
the treated used oil goes down to the reactor for transesterification. The catalyst and methanol is
fed using a funnel; mixed to oil and heated by heating coil, electric motor and agitator for
biodiesel and crude glycerin separation.

After separation, the biodiesel can be extracted by another valve at the side of the reactor
tank. The crude glycerin goes down to the evaporator for excess methanol recovery using heating
coils. The vaporized methanol advances to the condenser that uses cooling water that passes
through coils for further condensation. The liquid methanol is then collected through a valve at
the bottom of the condenser.

Drawing Sketch: WCO Gravitational Prototype

 3.3 Operation/Testing Procedure

3.3.1 Operation

Operating a biodiesel converter is not only focused on the machine but also in the process
itself. Knowing the quality of the oil is important to produce a good quality of biodiesel. By the
use of titration, the amount of chemicals to be used in the process will be measured. Then the
machine will handle the rest, heating, mixing and the separation of biodiesel, glycerin and excess
methanol will take place in the biodiesel converter. Every tank is set to their assigned
temperature for different stages and procedures. Motor for mixing is set to the right speed to
achieve the right speed for transesterification.

3.3.2 Functionality test

The functionality test was done after the prototype construction was finished. It was done
to assure the prototype will work accordingly when tested in the experimental test of converting
oil to biodiesel. The test includes operations like heating of the coils, filtration of heated oil,
mixing of oil, methanol and potassium hydroxide using mixing blades connected to a motor. The
first tank is made for preheating the oil. It reached the needed temperature to make the oil flow
effortlessly to the next tank. The second tank is made for filtrating oil so dirt, charred food and
other non-oil materials it did its job and do not permit other materials other than oil to pass
through. Important part of the biodiesel converter is the reactor, it reached the need speed in
order to mix the biodiesel properly. It has also a heating coil that reached the right temperature
needed. Then it goes to the evaporator where the glycerin and excess methanol will be separated
which did its job properly. Then the evaporated methanol is harvested in the condenser; hence
the prototype pass the functionality test.
3.3.3 Biodiesel Conversion System Test

The prototype biodiesel converter was tested in an experiment using vegetable oil. A total
of 25L of oil is subjected for the conversion of oil to biodiesel it is classified by the titration test
as average used oil. Expected outputs based on the objectives of the study are to produce almost
74% biodiesel from the oil, use the flow of gravity as pump and produce an good quality of
biodiesel. Using the prototype said objectives are reached and did an excellent job in the
experiment.

3.6 Instruments and Techniques Used

Thermocouple is a sensor used to measure temperature. Thermocouples consist of two wire legs

made from different metals. The wires legs are welded together at one end, creating a junction.
Propeller mixers are used for mixing
liquids in a wide range of viscosities. They are
suitable for the formation of low-viscosity
emulsions, for dissolving applications and for liquid-
phase reactions.

Sight glass  is a type of level sensor, a transparent tube through which the operator of a tank or 
can observe the separation of oil and glycerin,
Oil heater he high specific heat capacity allows the oil to effectively transfer thermal
energy from the heating element, while the oil's high boiling point allows it to remain in
the liquid phase for the purpose of heating, so that the heater does not have to be a high pressure
vessel.

Thermostat is a component which senses

the temperature of a system so that the system's
temperature is maintained near a desired setpoint.
 Ball Valves are used for flow and pressure control and shut off for oil.

Filtration Net are used to for

the isolation of the solid particles that may contaminate the oil.

CHAPTER 4
 Materials and Costing

Bill of Materials

Below are the list of materials with their corresponding prices needed in the construction

of Biodiesel Prototype that will convert Waste Cooking Oil into Biodiesel.

PROTOTYPE MATERIALS
Material Description Quantity Unit Cost Amount
Ball Valve (3/4 inch) 4 pcs. ₱450 ₱1800
Ball Valve (1/4 inch) 4 pcs. ₱480 ₱1920
Ball Valve (1/2) 4 pcs. ₱250 ₱1000
Thermostat 3 pcs. ₱900 ₱2700
Side Glass (14 inch) 2 pcs. ₱2500 ₱5000
Stainless Steel 304s 5 pcs. ₱1500 ₱7500

sheet

(1.0*1220x2440MM)
Stainless Steel Square 8 pcs. ₱450 ₱3600

Bar (1.5MM)
Foot Adjuster 4 pcs. ₱350 ₱1400
Thermo Couple 2 pcs. ₱500 ₱1000
Nipple (1/4 inch) 4 pcs. ₱130 ₱540
Nipple (1/2 inch) 4 pcs. ₱100 ₱400
Nipple (3/4 inch) 4 pcs. ₱90 ₱360
Fittings (1/2 inch) 13 pcs. ₱130 ₱1690
Fittings (1/2 inch) 5 pcs. ₱115 ₱575
Copper Tube 2 meters ₱110 ₱220
Heater 3 pcs. ₱500 ₱1500
Electrical Tape 2 pcs. ₱20 ₱40
Wire (2.0) 2 meters ₱28 ₱56
Teplon Tape 2 pcs. ₱23 ₱46
Cable Tie 75 pcs. ₱90
Switch on/off 1 pc. ₱49 ₱49
Flap Disc 1 pc. ₱79 ₱79
Steel Cutter 2 pcs. ₱130 ₱260
Flat Washer (5/16) 6 pcs. ₱10 ₱60
 Welding Rod ½ kg ₱200 ₱200
SUBTOTAL ₱32,085

EQUIPMENTS
Material Description Quantity Unit Cost Amount
Electric Motor 1 ₱1500 ₱1500
SUBTOTAL ₱1500

CHEMICAL
QUANTITY UNIT ARTICLES UNIT PRICE AMOUNT
10 Lt METHANOL TECH. ₱61.00 ₱610.00
POTASSIUM HYDROXIDE
2 Kg ₱100.00 ₱200.00
TECH.
500 Ml PHENOLPHTHALEIN LIQUID ₱138.00 ₱138.00
SUBTOTAL ₱948.00

APPARATUS
QUANTITY UNIT ARTICLES UNIT PRICE AMOUNT
3 PCS APPARATUS BEAKER ₱198.00 ₱594.00
1 PC APPARATUS GLASS ₱198.00 ₱198.00

FUNE
4 PCS APPARATUS TEST TUBE ₱20.00 ₱80.00
1 PC APPARATUS TEST TUBE ₱255.00 ₱255.00
2 PCS SURGICAL GLOVES ₱8.00 ₱16.00
1 PC LABORATORY GOGGLES ₱98.00 ₱98.00
1 PC POCKET SCALE ₱575.00 ₱575.00
1 PC SAFETY GOGGLES ₱55.00 ₱55.00
2 PCS DUST MASK ₱35.00 ₱70.00
5 PCS SYRINGE ₱10.00 ₱50.00
SUBTOTAL ₱1991.00
 TESTING
SAMPLE SAMPLE TESTING TEST TEST NO. OF TOTAL

CODE REQUESTED METHOD FEE SAMPLES/U

NITS
BIODIESEL OCS-2019- API GRAVITY ASTM 700.00 1 700.00

1272 OR SPECIFIC D4052 OR

GRAVITY OR ASTM

DENSITY D1298
BIODIESEL OCS-2019- TOTAL ACID ASTM D 520.00 1 520.00

1272 NUMBER 974

BIODIESEL OCS-2019- API GRAVITY ASTM 700.00 1 700.00

1272 OR SPECIFIC D4052 OR

GRAVITY OR ASTM

DENSITY D1298
BIODIESEL OCS-2019- HEATING ASTM D240 1,500. 1 1,500.00

1272 VALUE 00
BIODIESEL OCS-2019- FLASHPOINT . 700.00 1 700.00

1272
BIODIESEL OCS-2019- VISCOCITY ASTM 840.00 1 840.00

1272 (BROOKFIELD)
BIODIESEL OCS-2019- POUR PLANT ASTM D97 1,500. 1 1,500.00

1272 00

SUB-TOTAL 6,460.00
DISCOUNT 1,292.00
TOTAL 5,168.00

Other Expenses
Transportation ₱6000
SUBTOTAL ₱6000
TOTAL: ₱47,692
Production Cost of Biodiesel

1. Prices of chemicals and materials used in making Biodiesel.

 Methanol ₱61.00/liter

 Potassium Hydroxide (KOH) ₱50.00/50 gram

WCO/animal fats: Free from supplier

2. Cost of mixture needed in making Biodiesel per liter of WCO.

 WCO (Free)

 Methanol needed is measured from 20% of WCO, where 1 liter of WCO needs 200ml of

methanol where ₱12.2 per 200ml

Potassium Hydroxide (KOH): needed 10 gram per liter of WCO based from titration ₱10.00 per

10grams

3. Ratio of mixture

 Using 1liter of WCO, we need 200ml of methanol and 10grams of Potassium Hydroxide

(KOH)

Price Value:

WCO ₱0.00 (Free)

CH3 OH (Methanol) = ₱12.2

Potassium Hydroxide (KOH) = ₱10.00

Total: ₱32.2

4. Finish product
  Biodiesel

 By product glycerine

5. Quantity procedure

From 1liter of WCO and 200ml of Methanol and 10grams of KOH we get:

 900ml of Biodiesel

 150ml of Glycerine

6. Price of pure Biodiesel based on the President of Biodiesel in the Philippines.

Pure Biodiesel price: ₱80.00/liter

Price per 100ml = ₱8.00

 Price of glycerine per liter

Price value ₱57.0714/gal (1gal/3.785L) = ₱15.08/L

Price per 100ml = ₱1.508

Price per 50ml = ₱0.754

7. Total Biodiesel produced base from 20liters of WCO per production

 Total product 900ml x 20 = 18liters of Biodiesel

 Total glycerine produce 150ml x 20 = 3liters of glycerine

But:

In the glycerine produced, it has approximately 23% by volume of methanol we used.

  Solving for how much methanol can recover:

We put 4liters of methanol in 20liters of animal fats

4liters of methanol x 0.23 = 0.21liter = 920ml

 For the price of methanol recovered in the methanol recapturing unit:

Methanol price: ₱12.2 per 200ml

Price recovered ₱12.2 per 200ml x 920ml = ₱56.12

 Total glycerine produce: amount of glycerine – amount of methanol recovered

Total glycerine produce = 3000ml – 920ml = 2080ml

8. Cost of production

Cp = ₱32.2 x 20 = ₱644.00

9. Total cost of production

Tcp = Cost of production – price recover from methanol

Tcp = ₱644.00 - ₱56.12

Tcp = ₱587.88

10. Total price of product from quantity procedure

 Biodiesel

18000ml (₱8/100ml) = ₱1440

 Glycerine

2080ml (₱0.754/50ml) = ₱31.37

11. Total sale = sum of all sale

Biodiesel = ₱1440

Glycerine = 31.37

Total = ₱1471.37

12. Power consumption

Rate of Pampanga II Electric Cooperative, Inc. = ₱10.23/kWh

 Motor

Power consumption = 250W

Duration = 1hr

Price consumption rate = ₱10.23/kWh x 704 W/hr (1kW/1000W) = ₱7.20

 For Water Heater

3 Water Heater

Power Consumption: 1000W (1kW/1000W) = 1kW/heater x 3 = 3kW

Duration 20mins/heater (3 heater) = 60mins (1hour)

Price for consumption

Rate ₱10.23/kWh (3kW)(1hr) = ₱30.68

13. For Profit

Profit = Total Scale – Total Cost of Production

Profit = ₱1471.37 - ₱587.88 - ₱37.88

Profit = ₱845.61/day

14. For net profit in 160 days if we supply 18 liters of pure Biodiesel a day to buyer:

Net Profit = 845.61/day x 160 days

Net Profit = ₱135,297.04

For Net Annual Profit

15. Net Annual Profit

₱845.61/day x (365days/1 year) = ₱308,646.37/year