Simulation of Biodiesel Production from Black Soldier Fly Larvae

(BSFL) using Transesterification Method with NaOH Catalyst

Kuntarsih, Putri Ayu1; Raga, Aryo Fandi 1; Barumun, Riskina Zogi 1;

Andika, Riezqa1,2; Gozan, Misri1,2
Corresponding author: rzq_andika@hotmail.com; mgozan@ui.ac.id

1
Bioprocess Engineering Program, Department of Chemical Engineering, Faculty of
Engineering, Universitas Indonesia, Kampus UI Depok 16424, Indonesia
2
Research Centre for Biomass Valorization-Universitas Indonesia (RCBV-UI), Faculty of
Engineering, Universitas Indonesia, Kampus UI Depok 16424, Indonesia

Abstract:
Black Soldier Fly Larvae is an oleaginous insect, can assimilate several organic wastes for fat
accumulation, thus serving as a promosing energy, biodiesel production. This study employs
the SuperPro Designer software to simulate the transesterification process for biodiesel
production from BSFL. The transesterification method is utilized to convert lipid rich BSFL
biomass that catalyzed by sodium hydroxide (NaOH) into biodiesel, a sustainable and eco-
friendly alternative to conventional fossil fuels. Biocatalyst alcalase enzyme was evaluated for
their catalytic activity in the reaction. A maximum biodiesel yield of 62,39% was obtained at
a temperature of 60°C and reaction time of 3,0 hour. Under the optimal reaction conditions and
enzyme regeneration process, Alcalase could be reused many times, yielding 59,8% biodiesel.
Furthermore, the economic feasibility of the biodiesel production process is also analyzed using
cost data integrated into SuperPro Designer. The economic showed that within the production
of capacity 239,39 kg/batch obtained an Internal Rate of Return 24,35%, payback period 3,06
years, and Net Present Value 5.335.000 $. The results aim to contribute valuable insights into
the economic viability and potential scalability of BSFL-based biodiesel production,
emphasizing its significance as a renewable energy source and waste-to-energy solution.
Keywords: Biodiesel, Black Soldier Fly Larvae, Transesterification, Simulation, SuperPro
Designer, Sodium hydroxide, Alcalase enzym, Yield, Economic Analysis

INTRODUCTION
Energy crisis occurs because of the imbalance between the rate of energy consumption
and the availability of energy supply. This is due to the massive industrialization of the world
and the rapid population growth. the rapid rate of population growth. Based on data on Energy
Efficiency in Indonesia in 2017 by (International Energy Agency, 2017) International Energy
Agency (IEA), the total final consumption between 2000 and 2015 grew by 36%, with
petroleum 39% and biomass 35% as the dominant sources. The data shows that dependence on
fuel oil (BBM) is still very high. Oil reserves in 2014 amounted to 3.6 billion barrels, natural
gas to 100.3 TCF, and coal reserves to 32.27 billion tons. If it is assumed that there are no new
reserve discoveries based on the 2014 Reserve/Production ratio, then oil will run out in 12
years, gas in 37 years, and coal in 70 years. These reserves will be depleted even faster than
this estimate because the trend of fossil energy production continues to increase.
The waste problem is also getting out of control. Piles of waste not only damage
aesthetic value, but also have an impact on the emergence of foul odors, health problems, and
threats to environmental sustainability. As much as 60-70% is organic waste including kitchen
waste (food waste) (Trihadiningrum et al., 2017). In fact, Indonesia is the second largest
producer of food waste in the world. Organic waste has the potential to be optimally utilized.
However, waste management in Indonesia is limited to landfilling or piling up waste in landfills
without further processing. Even though the funds disbursed for transporting waste to landfills
are costly. The act of transferring waste to landfill through this system is an inappropriate
solution, so it is necessary to find a waste management system that are more effective and
efficient.
Black Soldier Fly (BSF) larvae are reliable degraders that can break down 50-55% of
organic waste in some phases of their life. In addition, BSF also has a high level of enzyme
activity. The presence of BSF larvae in the environment is considered safer for human health
because it can reduce waste contamination with pathogenic bacteria. BSF can degrade organic
waste with a life phase of 21 days. BSF pupae are known to contain 35% fat, which has
potential as a raw material for environmentally friendly energy in the form of biodiesel (Popa
& Green, 2012). BSF larvae are high in fat, which has the potential to be a source of biodiesel.
The biodiesel production process from BSF fat also produces aspartic and glutamic acid that
have economic value. Therefore, BSF larvae have great potential to solve the problem of
organic waste correlated with energy demand.
This paper delves into a novel approach to biodiesel production, focusing on utilizing
Black Soldier Fly (Hermetia illucens) larvae as a sustainable and environmentally friendly
feedstock. Black Soldier Fly larvae are known for their voracious appetite and efficient
conversion of organic waste into valuable biomass. Leveraging these attributes, this study
investigates the feasibility of harnessing Black Soldier Fly larvae as a biodiesel feedstock.
Furthermore, the enzymatic hydrolysis process employing Alcalase, an alkaline protease
enzyme, is introduced to enhance the efficiency of lipid extraction from the larvae. Enzymatic
hydrolysis offers advantages such as mild reaction conditions, higher selectivity, and reduced
environmental impact compared to traditional chemical methods. To complete the biodiesel
production process, sodium hydroxide (NaOH) is utilized as a catalyst for transesterification,
ensuring the conversion of the extracted lipids into biodiesel. This paper aims to elucidate the
synergistic effects of enzymatic hydrolysis and transesterification processes, providing
valuable insights into the optimization of biodiesel production using Black Soldier Fly larvae.
In summary, this research endeavors to contribute to the growing body of knowledge
on sustainable biodiesel production by examining the potential of Black Soldier Fly larvae as
a feedstock, coupled with enzymatic hydrolysis and transesterification processes. The findings
of this study hold implications for both the bioenergy and waste management sectors, offering
a multifaceted solution to the challenges faced by Indonesia and other regions seeking
sustainable alternatives in the quest for a greener energy future.

1. MATERIAL AND METHOD

Material
All simulations presented in this paper were conducted utilizing SuperPro 13th version
software, made available under the academic license for the Bioprocess Engineering
Major at the University of Indonesia. The raw material employed for the biodiesel
production process is Black Soldier Fly Larvae (BSFL). The chemical composition of the
BSFL utilized is characterized by specific components: 15.91% Exoskeleton, 42.71%
Proteins, 25.626% Lipid, 5.756% Ash, and 10% Water, as reported by Zulkifli (2022).
The lipid fraction further consists of 18.535% palmitic acid, 31.95% stearic acid, 38.6%
lauric acid, and 10.88% myristic acid. Concurrently, the protein content primarily
comprises glutamic acid and aspartic acid. A feed volume of 1500 kg is employed per
batch production.
Methodology
The procedural series involved in the synthesis of biodiesel from BSFL (Black Soldier Fly
Larvae) can be elucidated through examination of the Block Flow Diagram presented here:

Figure 1. Block Flow Diagram for Production of Biodiesel From BSFL

The production process initiates with the cleansing of Black Soldier Fly Larvae (BSFL)
feed, a crucial step aimed at removing impurities such as ash and exoskeleton residues.
The washed BSFL is then subjected to grinding using a grinder, reducing its particle size
 to enhance reactivity in subsequent reactor and process stages. Subsequently, the
processed material undergoes protein extraction through cell culture employing a
hydrolysis reaction catalyzed by the alcalase enzyme at a temperature of 37 °C. This
extraction process yields a high conversion rate, resulting in a protein content of
approximately 78%. Following protein extraction, the next phase involves the separation
of glutamic acid and aspartic acid from the main stream, constituting the primary
byproducts of the process.
The primary stream is directed to the reactor for the transesterification process, where
lipids are reacted with methanol under basic conditions. Sodium hydroxide (NaOH) is
employed as a catalyst, and the reaction is conducted at a temperature of 60°C to yield
biodiesel. Byproducts, including glycerol, are directed to the waste stream following
passage through a centrifugation unit. This unit plays a pivotal role in separating impurities
such as methanol, proteins, and water from the byproducts, ensuring the effective disposal
of unwanted elements.
The purification process of biodiesel commences with neutralization, serving as an
auxiliary unit for waste treatment. This involves the use of hydrochloric acid (HCl) as a
catalyst to generate a salt solution, such as NaCl. To achieve a biodiesel product of high
purity, a flash evaporation method is applied at 120 °C and 1 atm, with the incoming
stream preheated to 110 °C. The resulting biodiesel, constituting the main product, is
directed to the understream and stored in a storage unit equipped with a cooling system to
maintain a temperature of 25 °C. Simultaneously, the other stream generated from the
flash evaporation process undergoes distillation to separate lauric acid and palmitic acid
as byproducts, ensuring their isolation at high levels of purity.
The economic viability of the simulation is scrutinized through an evaluation of the impact
of internal rate of return (IRR), net present value (NPV), and payback time parameters on
the overall cost of the simulation. The analysis commences by selecting the most
expensive raw material and systematically adjusting its price at intervals of 80%, 90%,
100%, 110%, and 120%. This methodology is then replicated for the pricing of the primary
product, Biodiesel, as well as byproducts including Aspartic acid, Glutamic acid, Lauric
acid, and Palmitic acid. Additionally, variations in labor costs are considered, assumed to
align with the average income level in Majalengka, West Java. The resulting percentage
effects and changes in prices are visually represented, facilitating the assessment of trends
emerging from the simulated production process of Biodiesel.
2. RESULT AND DISCUSSION

Process Schematic
The biodiesel production process from Black Soldier Fly Larvae (BSFL) consists
of three main processes, namely pre-treatment of raw BSFL, transesterification reaction,
and purification process. In the pretreatment stage, special treatments are carried out on
the raw material before the hydrolysis process with the alcalase enzyme to extract proteins
into amino acids in the form of glutamic acid and aspartic acid which will become by-
products in the biodiesel production process. Furthermore, the fatty acids contained in
BSFL will go through the transesterification stage with the aim of processing these fatty
acids into the main product, biodiesel. The transesterification process is carried out with
the help of NaOH catalyst and methanol. Biodiesel will be purified in order to obtain a
product with a high level of purity and the acquisition of other by-products in the form of
lauric acid and palmitic acid. This process was simulated and optimized using SuperPro
Designer v.13 software, showing a production capacity of 239,4154 kg of biodiesel with
a purity level of 99.987% from the incoming feed of raw BSFL of 1500kg per batch. This
shows a biodiesel yield of 62,3% (kg Biodiesel produced per kg BSFL input).

Figure 2. Flowsheet Simulation of Biodiesel from BSFL.

The duration of the biodiesel production process can be seen through the gantt chart
table.

Figure 3. Gantt Chart of Process

In this process, the fermentation stage is the process that takes the most time around 8 hour
per batch. The process that occurs in the device is one of the essential stages to produce a
high yielding rate. In the fermenter, the alcalase enzyme is used. The fermentation stage
is a critical process in the production of biodiesel, as it serves as the precursor for the
formation of feedstocks rich in lipids, which are essential for the subsequent
transesterification process. The lipid composition of the feedstock significantly influences
the quality and characteristics of the biodiesel produced. The fermentation process allows
for the control and optimization of lipid content in the biomass, ensuring a feedstock that
is conducive to high biodiesel yields and quality. Alcalase enzym derived from Bacillus
licheniformis, is primarily as a serine endopeptidase, also known as a protease. It would
hydrolyze proteins, breaking peptide bonds within protein molecules to produce peptides
and amino acids, also processing the conversion of high-content lipids that will be
processed into biodiesel.

Table 1. Material component streamTable

The transesterification process can be optimized by carefully selecting catalysts,

adjusting reaction parameters, and ensuring efficient mixing. Utilizing catalysts such as
alkali or enzymes requires a balanced approach, considering factors like reaction time,
temperature, and catalyst concentration. Optimizing the biodiesel production process
also involves fine-tuning the fermentation transesterification stages to maximize yield
and efficiency which converts lipids into biodiesel. The total lipid converted in the
reactor was 37.53% with a yield of biodiesel formed after passing this reaction is 62,39%
with 239.39 kg/batch

.
Figure 4. Result of Outlet Stream Product in Reactor

Integration of the fermentation and transesterification processes is crucial for

overall optimization. This involves designing a seamless workflow where the lipid-rich
biomass generated in the fermentation stage seamlessly feeds into the transesterification
process. Efficient separation and purification methods ensure that impurities do not
negatively impact the transesterification reaction. Recycling of by-products and waste
streams can also enhance the overall sustainability of the biodiesel production process.

Equipment Cost
The equipment cost for the simulation process plays a pivotal role in determining the
overall economic feasibility and sustainability of biodiesel production from Black Soldier
Fly Larvae (BSFL). In the context of SuperPro Designer simulation, equipment costs
encompass a wide range of components, including reactors, separation units, and
monitoring instruments. The selection and sizing of these components are critical factors
influencing the efficiency and scalability of the biodiesel production process. Optimizing
equipment specifications, considering factors such as capacity, material compatibility, and
energy efficiency, becomes imperative to strike a balance between initial investment and
long-term operational costs. The price of operating equipment is taken with the latest price
reference from the marketplace Alibaba and Indiamart. The price calculation is assumed
to include transportation costs for shipping from the supplier to the destination port.
Reference equipment prices from Alibaba with the use of the US dollar rate. As for the
price of equipment with reference from indiamart, the conversion of currency exchange
rate is 1 rupee = 0.012 $.

Table 2. List of Equipment Cost

No Equipment Price Source
.
1. Washing Machine $6.600,00 Washer Bulk Flow 500kg
(Bulk Flow)

2. Bioreactor $8.000,00 Bioreactor 1500L

3. Decanter centrifuge $50.000 Centrifuge
4. Flash Drum $1.210,00 Flash Drum 1000-5000L
5. Grinder $450,00 Grinder 700 kg
6. Heater $1.210,00 Stainless Steel Heater
7. Microfilter Membrane $22.000,00 Microfilter Membrane Cross
Flow 50m2
8. Stirred Reactor $18.000,00 Reactor 5000 L
9. Neutralizer $1.405,00 Neutralizer
10. Vertical on Legs $1.137,00 Storage Tank 1000-10000 L
Storage Tank
11. Mixing Vessel $2.273,00 High Pressure Mixing Vessel
12. Flow Splitter $100,00 Flow Splitter
13. Distillation Collumn $3.631,00 Distillation Collumns 100L -
100 ton
14. Freeze-Dryer $36.000,00 Vacuum Freeze Dryer

Plant Location
Several considerations were taken into account in determining the location for our
biodiesel production plant, including aspects such as raw material availability,
infrastructure and accessibility, energy sources, labor availability, environmental factors,
and market connectivity. Based on these considerations, our group selected the Bogor
region as the site for the biodiesel production plant utilizing Black Soldier Fly Larvae
(BSFL) as the raw material. The Bogor region boasts a climate conducive to BSFL
growth, the availability of agricultural facilities, and well-established transportation
infrastructure. Furthermore, the proximity of Bogor to the capital city, Jakarta, facilitates
the distribution of biodiesel products to a broader market.

Labor Cost
The labor costs associated with each operation undergo standardization, referencing the
Regional Minimum Wage (UMR) for the city of Bogor, West Java, as specified by
Minister of Manpower Regulation Number 18 of 2022. This standardization is achieved
using the Alpha 0.2 coefficient, resulting in a fixed value of IDR 4.639.429. The monthly
wage is subsequently converted to establish the hourly wage rate. Assuming a standard 8-
hour workday over 5 days per week, the determined labor cost for operators is established
at $4 per hour.

Economic Analysis
Total Capital Investment
Operating Cost
Profitability Analysis
The selling price and market for selling Aspartic Acid, Glutamic Acid, Palmitic Acid,
Lauric Acid, and Biodiesel.
• Aspartic Acid
The selling price of Aspartic Acid products is 12 USD/kg.
• Glutamic Acid
The selling price of Glutamic Acid products is 4,2 USD/kg.
• Palmitic Acid
The selling price of Palmitic Acid products is 1,68 USD/kg.
• Lauric Acid
The selling price of Lauric Acid products is 3 USD/kg.
• Biodiesel
The selling price of Biodiesel products is 1,08 USD/kg.

Internal Rate of Return (IRR)

Net Present Value (NPV)

Based on the selling price, obtained NPV value of 5,225,000 USD
𝐶
NPV =∑𝑇𝑡=1 (1+𝑟)
𝑡
𝑡 − 𝐶0

A project is considered viable if its Net Present Value (NPV) is equal to or greater
than zero, signifying that the project will be beneficial throughout its productive lifespan.
The NPV value for the design of this plant is notably positive, amounting to 5,225,000
USD, suggesting that investing in the plant is a sound decision.

Payback Period (PBP)

Based on the selling price, obtained PBP value of 3,06 years.
The payback period is the time it takes to recover the initial investment in a project
or investment. The relatively short payback period of 3,06 years, which is less than half of
the plant's expected lifespan, has the potential to attract investors to fund the construction
of the integrated citric acid plant. The economic metrics, including Internal Rate of Return
(IRR), NPV, and Payback Period (PBP), affirm the economic feasibility of the proposed
plant design.

Sensitivity Analysis
1) Raw Material
The cost of the utilized raw materials, namely the price of Dried Black Soldier
Fly Larvae (BSFL), under ideal conditions, amounts to $1/kg, while the ideal
price for Alcalase Enzyme is $30/kg. These prices are subsequently subjected
to variations to conduct an economic analysis, as delineated in the table below:
Table 3. Raw Material sensitivity

2) Revenue
The revenue values considered include the ideal selling prices for Biodiesel,
Lauric Acid, Palmitic Acid, Glutamic Acid, and Aspartic Acid, which are
$1.08/kg, $3/kg, $1.68/kg, $4.2/kg, and $12/kg, respectively. These ideal selling
prices are subjected to variations to perform an economic analysis, as detailed
in the table below :
Table 4. Revenue sensitivity

3) Labor Cost
The labor costs associated with each operation undergo standardization,
referencing the Regional Minimum Wage (UMR) for the city of Bogor, West
Java, as specified by Minister of Manpower Regulation Number 18 of 2022.
This standardization is achieved using the Alpha 0.2 coefficient, resulting in a
fixed value of IDR 4.639.429. These ideal labor cost are subjected to variations
to perform an economic analysis, as detailed in the table below :
 Table 5. Labor cost sensitivity

Figure 5 . Graph conomic Sensitivity Analysis of (a) IRR,

(b) Payback time, (c) NPV.

From the sensitivity analysis conducted by examining the values of IRR, NPV, and PBP
across various percentage variations in raw materials, revenue, and labor (80%, 90%,
100%, 110%, 120%), it can be inferred that a decrease or increase in revenue has the
most significant impact on the economic viability of this biodiesel plant. While changes
in raw material prices also influence the plant's economics, their effect is comparatively
smaller than that of revenue. As for labor, this factor exhibits negligible impact on the
plant's economic viability, possibly attributed to the limited quantity of labor utilized and
the correspondingly modest labor costs.
 Positioning
Table 6. Positioning of the Simulation.
Parameter Aryo, Putri, and Nguyen, 2017
Riskina, 2023
Raw Material Black Soldier Fly Black Soldier Fly
Larvae Larvae
Production Transesterification Transesterification
Method
Enzyme Alcalase Novozym 435
Catalyst NaOH Novozym 435
Temperature 60°C 20-40°C
Time of 3h 4-12 h
Reaction
Yield 62,39% 56,78%

The table above shows the comparison between the research conducted by this study and
the previous study, conducted by Nguyen, 2017. This study focuses on the production of
biodiesel from black soldier fly larvae using the transesterification method, similar to the
previous study. The difference between these two studies is in the enzymes and catalysts
used, this study uses Alcalase enzyme as an enzyme and NaOH as a catalyst, while the
previous study used Novozym 435 as an enzyme as well as a catalyst.
In addition, this study requires a higher temperature and shorter time, namely 60°C for 3
hours, compared to the previous study which was at 20-40°C for 4-12 hours. The products
produced from these two studies were also different due to differences in enzymes and
catalysts used as well as the operating conditions used. The yield obtained in this study
was 62,39%, while the yield produced in the previous study was 56.78%.

CONCLUSION
The biodiesel production process from Black Soldier Fly Larvae (BSFL) consists of 3 main
processes, namely pre-treatment of raw BSFL, transesterification reaction, and purification
process. This process was simulated and optimized using SuperPro Designer v.13 software,
showing a production capacity of 239,37 kg of biodiesel with a purity level of 99.987% from
the incoming feed of raw BSFL of 1500kg per batch. This shows a biodiesel yield of 62,39%
(kg Biodiesel produced per kg BSFL input). Besides the main product of biodiesel, by-products
were also obtained which are 370 kg/batch of aspartic acid and 413,14 kg/batch of glutamic
acid.
From economic perspectives, the simulation results for biodiesel production from Black
Soldier Fly Larvae (BSFL) present a promising economic outlook, with a calculated Internal
Rate of Return (IRR) of 24,05%, a Payback Period of 3.06 years, and a Net Present Value
(NPV) of $5,335,000. These metrics collectively indicate the potential financial viability of the
proposed biodiesel production process. An IRR of 24,05% exceeds typical industry
benchmarks, suggesting a robust investment opportunity. The relatively short payback period
underscores the efficiency with which the initial capital investment is recovered. Moreover, a
positive NPV of $5,335,000 signals the net positive value of the project over its lifespan. While
these financial indicators are encouraging, their sufficiency in the industry context depends on
various factors such as market conditions, regulatory support, and competition. Further
consideration of risk factors, market dynamics, and ongoing operational costs will be essential
to make informed decisions about the project's viability and its potential contribution to the
biodiesel industry. Overall, the positive financial metrics derived from the simulation provide
a strong foundation for further exploration and consideration of implementing the biodiesel
production from BSFL at an industrial scale.
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