Essential Oil Distillation Plant Project

Essential oil distillation plant project
Acknowledgement
We would like to acknowledge our advisor Ato Abebe kebede, the principal investigator for this
project “developing low cost essential oil distillation plant” for his assistance and advice that brings
the project to success.
Our acknowledgement is also extended to Ato Mesele Hayelom for his advice during the project work.
In addition, we are grateful to Dr.Redi form geography department for his valuable comments.
Finally, we would like to thank our department, the department of mechanical engineering for the
financial and material support during our work. Our thanks also go to our friends for their critical
comments during our work.
i
Final year project By: Filimon K & Girma G
Abstract
This report briefs about; what essential oils are their economic value and their industrial
use; essential oils are the high quality oily liquid obtained from plants through a variety
of processes. The oil usually has the taste and smell of the original plant. Essential oils
are called volatile because most of them are easily vaporized. The only theories for
calling such oil "essential" are that the oils were believed essential to life and they were
the "essence" of the plant.
In addition, the different methods for production of essential oils such as distillation
(water or hydro-distillation, water and steam distillation and steam distillation), carbon
dioxide extraction, cold pressing, solvent extraction, etc. are explained briefly.
More over the selected method of production for essential oils in this design, the energy
modeling and the different components of the distillation plant including the design of the
components, and the materials required for the construction of the distillation plant are
discussed briefly.
ii
Objective
Extracting of essential oils by steam distillation requires a process that commonly uses
large, centralized equipments like boilers, stills, condensers and separators. Such
equipments require a high initial purchase that is unmanageable for many small farmers
and even groups of farmers in most developing countries. Further, some essential oils
come from extremely delicate flowers that must be processed soon after harvesting. Thus,
for functional and economic reasons, there is a need for small-scale, decentralized steam
distilling equipment. Therefore, the objective of this project is to design a low cost
essential oil distillation plant, which can be manufactured in medium workshops using
locally available materials.
iii
Table of content
Page number
Acknowledgement ............................................................................................................... i
Abstract ............................................................................................................................... ii
Objective ............................................................................................................................ iii
Limitations .......................................................................................................................... v
CHAPTER 1 ....................................................................................................................... 1
ESSENTIAL OILS ............................................................................................................... 1
1.1 Introduction ............................................................................................................... 1
1.2 Industrial use of essential oils ................................................................................... 2
1.3 Ethiopian essential oils ............................................................................................. 4
CHAPTER 2 ....................................................................................................................... 5
ESSENTIAL OIL PRODUCTION ....................................................................................... 5
2.1 Distillation................................................................................................................. 5
2.1.1 Water Distillation............................................................................................... 6
2.1.2 Water and steam Distillation ............................................................................. 8
2.1.3 Steam Distillation............................................................................................. 10
2.2 Carbon Dioxide Extraction ..................................................................................... 12
2.3 Cold pressing .......................................................................................................... 12
2.4 Solvent Extraction ................................................................................................... 13
CHAPTER 3 ..................................................................................................................... 14
DESIGN APPROACH ....................................................................................................... 14
3. 1 Production method selection .................................................................................. 14
3.2 Energy modeling ..................................................................................................... 15
CHAPTER 4 ..................................................................................................................... 22
DESTILATION PLANT DESIGN ...................................................................................... 22
4.1 Steam generators ..................................................................................................... 22
4.2 steam generator mountings ..................................................................................... 23
4.2 Still .......................................................................................................................... 27
4.3 Separator ................................................................................................................. 29
4.5 Steam generator tank Design .................................................................................. 31
4.6 Condenser design (shell and tube type) .................................................................. 39
CHAPTER 5 ..................................................................................................................... 52
MATERIAL AND COST ESTIMATION.................................................................... 52
Conclusion ........................................................................................................................ 54
Recommendation ............................................................................................................... 55
Bibliography ..................................................................................................................... 56
iv
Limitations
The plant material property such as density of leaf, moisture content and specific heat
capacity of the leaf are very difficult to obtain in a literature.
References are not available. Though certain references are available in certain websites
their technological background is not given due to copy right.
Since the industry is not common in our country, we face a problem to get experimental
data, which are important for the design of the distillation plant.
v
CHAPTER 1
ESSENTIAL OILS
1.1 Introduction
Essential oils are distilled volatile oils of plants materials that have strong aromatic
components. These aromatic substances are made up of different chemical compounds
that occur naturally in the plant. For example, alcohol, hydrocarbons, phenols, aldehydes,
esters and ketones are some of the major components.
Among all types of plants in the world, only about 700 plants are considered aromatic,
and therefore, they are all significant for the production of essential oils. Besides the
limited source of supply, the small amount of essential oils that are contained in each
aromatic plant makes it even more valuable.
Essential oils and plant extracts are the basis for the natural flavor and fragrance industry
worldwide. They are extensively used globally for food flavoring, fragrances,
aromatherapy and pharmaceuticals. The worldwide market for essential oils has been
estimated at US$2.6 billion, with an annual growth rate of 7.5%.
The widespread use of aromatic plant products by consumers around the world and
increasing international trade have been accompanied by attempts to identify new species
of potential interest, to bring them into cultivation from the wild, and to introduce them to
distant locations away from their places of origin. Among the aromatic substances of
natural origin, which are currently used by the pharmaceutical, perfumery, cosmetic, and
food industries, some are derived from plants, which have been cultivated for a long time
whereas others are still obtained from species, which grow abundantly in the wild.
In order to get the best quality and quantity of essential oils, extraction procedure seems
the key-controlling step. Factors such as types of plants, chemical make-up of oil, and
location of oil within the plant (root, bark, wood, branch, leaf, flower, fruit and/or seed)
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are to be considered prior to the extraction. Choosing a proper extraction method is also
important as well.
In general, there are four types of extraction methods:
 Distillation
 Carbon dioxide extraction
 Cold pressing and
 Solvent extraction
These extraction methods will be briefly discussed in the next chapter.
Applications of aromatic plants and volatile oils extracted from them include:
 direct culinary use: as fresh or dried herbs, spices and condiments;
 In perfumery, cosmetics, and household and personal hygiene products either

directly as major or minor ingredients or as raw materials for the extraction and
or synthesis of specific aroma chemicals;
 In food, and drink: as flavoring agents;
 In human and veterinary medicine: as components of pharmaceutical

preparations;
 In crop protection: as pesticides and insect repellents; and
 As antibacterial and antifungal agents in a range of situations.
1.2 Industrial use of essential oils

In addition to all application and use mentioned above essential oils are widely used in
industries including the flavor and fragrance industries as a source of flavor and aroma, in
the food and drink industries as processing and flavoring agents, in the paint, petroleum,
and in many other industrial transformations. The industrial uses of essential oils are
summarized in the following chart:
2
Cosmetics and toiletries:

-perfumes & sprays
Adhesives: Dental preparations: -creams
- cements -tooth pastes -deodorants
- Pastes & -mouth washes -colognes
glues -antiseptics -shaving preparations
- Tapes -cements -powders
-soaps & detergents
Medical & Veterinary

preparations
PHARMACEUTICALS Paper & printing industry
-carbon paper
-crayons
-inks
Essential -labels
Paints Industry Oils -writing paper
-paints -ribbons
-distempers
-diluents
-paint removers
-cleaning fluids
-air fresheners
Motor industry:
-polishes, cleaners
-seat upholstery
Insecticide preparations: & other plastic goods
-sprays
-repellents
-attractants Petroleum industries:
-disinfectants -solvents
-lubricating oils/wares
Rubber & plastics

-surgical gloves
Textile industry: Food & Beverages -rubber toys
-upholstery materials -liquors -water proofing components
-finishing materials -flavoring agents -general plastics
-preservatives
3
1.3 Ethiopian essential oils

Ethiopia is blessed with fertile soil, which can produce a wide variety of aroma plants
suitable for the extraction of essential oils for use as food flavorings, fragrances,
aromatherapy products or pharmaceuticals. Therefore there is potential for creating a new
agro-industry in Ethiopia, an industry, which could create higher earnings from land use,
as well as create job opportunities both on the land and in the manufacturing.
The following table summarizes some of the Ethiopian essential oil plants and their
commercial use.
Botanic name Amharic Family Yield Availability Commercial use

name W/W ( place in
% Ethiopia)
Coriandrum Dimbellal Apiaceae 0.2% Addis Ababa Perfumes and for flavoring
sativum L. Market, sweets, tobacco and
Ethiopia alcoholic beverages.
Foeniculum Ensilal Apiaceae 0.14% Addis Ababa, Food flavoring, in liqueur,

vulgare Mill. Ethiopia toothpaste (together with
mint oil), perfumes and in
pharmaceutical
preparations
Trachyspermu Netch Apiaceae 0.32% flavoring food
m ammi L azmud
Artemisia Chikugn Asteraceae Addis Ababa,
abyssinica (Compositae Ethiopia
Schultz-Bip. )
Artemisia afra African Artemisia 0.5% Dinshu Bale, Most widely used Southern
Jacq. wormwood afra Jacq. Ethiopia African medicinal plants
Artemisia Ariti Asteraceae 0.24 Addis Ababa,
rehan (Compositae % Ethiopia
)
Bidens Adey Abeba Asteraceae 0.04 Addis Ababa,
prestinaria (Compositae % Ethiopia
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CHAPTER 2
ESSENTIAL OIL PRODUCTION
There are different types of essential oil production methods. Some of them are
distillation (water or Hydro-distillation, water and steam distillation, steam distillation),
carbon dioxide extraction, cold pressing, solvent extraction, etc.
2.1 Distillation
“The art of distillation is the act of the invisible being made visible”
...Jeanne rose 2001
The vast majority of true essential oils are produced by distillation. There are different
processes used, however. In all of them, water is heated to produce steam, which carries
the most volatile chemicals of the aromatic material with it. The steam is then chilled (in
a condenser) and the resulting distillate is collected. The essential oil will normally float
on top of the Hydrosol (the distilled water component) and may be separated off.
Distillation is the most economical method of extracting essential oil from spices and
aromatic plant material. The main advantage of distillation is that it can generally be
carried out with some very simple equipment, close to the location of plant production.
Even in relatively remote locations, large quantities of material can be processed in a
relatively short time. Distillation is less labor intensive and has a lower labor skill
requirement than other extraction methods.
Preparation of material for distillation varies with the material to be distilled. Some
material must be distilled immediately after harvesting, whereas others can be (and are
best) stored for a day or two before distilling and finally there are materials which can be
stored indefinitely before distillation. In general, flowers should be distilled immediately,
5
whereas herbaceous material often benefits from wilting for one or two days before
distillation. Woody materials may need to be ground and/or soaked before distillation.
The preparation of the raw material, the packing of the still and the rate/type of
distillation can be determined for a particular essential oil crop from a literature or from
experimental trials.
Types of distillation
There are three basic types of essential oil distillation:
i. water distillation or "hydro distillation"
ii. water and steam distillation or "wet steam"
iii. steam distillation or "dry steam"
2.1.1 Water Distillation
Water distillation is the simplest of the three distillation methods. The principle of water
distillation is to boil a suspension of an aromatic plant material and water so that its
vapors can be condensed. The oil, which is immiscible with the water, is then separated.
Most water distillations are performed in rural areas where no access to a steam boiler is
possible, or if a satellite boiler is available, it complicates the process of oil production. In
water distillation, the plant material is always in direct contact with water. An extremely
important factor is that in stills where the water is boiled by direct contact with the fire,
the water present in the still must always be more than enough to last throughout the
distillation; otherwise, the plant material can overheat and burn. When this happens,
depending upon the plant material charge, off-notes (being fired by high temp)are formed
from Millard reactions, Strecker degradations and eventually the pyrolytic degradation of
the material. As a result, the oil can assume a variety of off-notes, generally known as
still notes.
Water distilled oils are commonly darker in color and have much stronger still notes than
oils produced by other methods. If the oil contains higher boiling components (phenols,
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alkenyl phenol ethers, or sesquiterpenes), the distillation time is increased over oils that
contain only monoterpene hydrocarbons and oxygenated constituents. It is generally not
possible to put enough water in the still and have it last for the whole distillation cycle.
To compensate for this, a cohabitation tube is placed in the side of the still and water is
constantly returned to the pot.
Water distillation is probably the simplest and cheapest method of extracting essential
oils, but the quality of the oil has the greatest potential to be modified due to the effects
of direct heating and the water contact.
As mentioned above, oils produced by water distillation tend to be of lower quality than
oils produced by other methods for the following reasons:
 The oil components like esters are sensitive to hydrolysis while others like
acyclic monoterpene hydrocarbons or aldehydes are susceptible to polymerization
(the pH of the water is often times reduced during distillation so that hydrolytic
reactions can be facilitated).
 Oxygenated components such as phenols have a tendency to partially dissolve in

the still water so their complete removal by distillation is not possible.
 As water distillations tend to be small (being operated by one or two people), it

takes a long time to accumulate much oil, so good quality oil is often times mixed
with bad quality oil.
 Water distillation is a slower process than either steam or water and steam
distillation; consequently, it is less energy efficient.
An advantage of water distillation is that for plant material that has a tendency to
agglomerate or to agglutinate into an impenetrable mass when steam is passed through it
(like rose petals), water distillation is reputed to be the preferred method of oil isolation.
Perhaps it can be concluded then that the only advantage of water distillation is that the
cost of process equipment is extremely low, the design of the stills, condensers and
collection flasks are simple, and the need for electricity is not prohibitive.
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Figure 2.1.1 Diagrammatic representation of water distillation unit where the plant
material is suspended in the water.
2.1.2 Water and steam Distillation
Water and steam distillation is an improved method, the still contains a grid which keeps
the plant material above the water level fig 2.1.2 .The water is boiled below the charge
and "wet" steam passes through the plant material. Consequently, if an open fire is used
the plant material is protected from direct heat.
Like water distillation, it is a widely used process in rural areas, as it does not require a
great deal more capital expenditure than water distillation. In addition, the design of
equipment that is used is generally very similar to that used in water distillation, only the
plant material is supported above the boiling water on a perforated grid. In fact, it has
become the traditional progression from water distillation to steam and water distillation.
It follows that once the rural distiller has produced a few batches of oil by water
distillation, there is a realization that the quality of oil that was produced is not very good
because of its still notes. As a result, some modifications are made. Using the same still, a
perforated grill, or plate is fashioned so that the plant material is raised above the water.
This reduces the capacity of the still but affords a better quality of oil. If the amount of
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water will not last long enough to allow the completion of distillation, a cohabitation tube
is attached and condensate water is added back to the still manually, thereby ensuring that
the water, which is being used as the steam source, will never run out. It is also believed
that this will, to some extent, control the loss of dissolved oxygenated constituents in the
Condensate water because the re-use of the condensate water will allow it to become
saturated with dissolved constituents, after which no more will dissolve in it.
In steam and water distillation, the plant material cannot be in direct contact with the fire
source beneath the still; however, the walls of the still are good conductors of heat so that
still notes can also be obtained from the thermal degradation reactions of plant material
that is touching the sides of the still. As the steam in the steam and water distillation
process is wet, a major drawback in this type of distillation is that it will make the plant
material quite wet. This will slow down distillation, as the steam has to vaporize the
water to allow it to condense further up the still, etc.
There is one way to prevent the lower plant material resting on the grid from becoming
Water logged. It requires the use of a baffle to prevent the water from boiling too
vigorously, resulting in direct hot water contact on the plant material. In addition to the
fact that the wetness of the lower plant material slows down the distillation, an
accumulation of water within the lower part of the still can cause it to reflux. This means
that in the lower portion of the still the water will constantly boil and condense which
will not only be detrimental to the steam passage through the charge, but it will also
dissolve some of the oil constituents.
The advantages of water and steam distillation over water distillation are as follows:
a. Higher oil yield
b. Oil components of the oil are less susceptible to hydrolysis and polymerization
c. If refluxing is controlled, then the loss of polar compounds is minimized
d. Oil quality produced by steam and water distillation is more reproducible
e. Steam and water distillation is a faster process than water distillation so it is
more energy efficient
9
Figure 2.1.2 Diagrammatic representation of a water and steam distillation unit with a baffle to
prevent direct water contact with the plant material on the perforated grid.
2.1.3 Steam Distillation
Steam distillation is the most advanced type of distillation, as the name suggests, steam
distillation is the process of distilling plant material with steam generated outside of the
still in a satellite steam generator generally referred to as a boiler. As in steam and water
distillation, the plant material is supported on a perforated grid above the steam inlet. A
real advantage in the satellite steam generation is that the amount of steam can be readily
controlled. An example of a modern steam distillation unit can be seen in Figure 2.1.3
Because steam is generated in a satellite boiler, the heat contact of the plant material will
be no higher than 100°C. Consequently, the amount of heat with which the plant material
will come in contact is acceptable and should not cause any thermal degradation of it.
The process of steam distillation is the most widely accepted process for the production
of essential oil on the large scale. Throughout the flavor and fragrance supply business, it
is a standard practice.
An obvious drawback to steam distillation is the much higher capital expenditure needed
to build such a facility. In some situations, such as the large scale production of low cost
oils such as rosemary, Chinese cedar wood, lemongrass, litsea cubeba, spike lavender,
eucalyptus, lemongrass, citronella, corn mint, etc.,. The world market prices of the oils
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are barely high enough to allow them to be produced by steam distillation without
amortizing the capital expenditure required to build the facility over a period of 10 years
or more.
Figure 2.1.3 Diagrammatic representation of steam distillation unit
The advantages and disadvantages of steam distillation are as follows:

 The amount of steam and the quality of the steam can be controlled.
 Lower risk of thermal degradation as temperature generally not above 100°C
 Most widely used process for the extraction of essential oils on a large scale
 Throughout the flavor and fragrance supply industry, it is the standard method
of extraction.
 There is a much higher capital requirement and with low-priced oils the pay
back period can be over 10 years.
 Requires higher level of technical skill and fabrication and repairs and
maintenance require a higher level of skill.
 Many variations of the process exist, e.g. batch, hydro diffusion, maceration
distillation, mobile stills and continuous distillation process.
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2.2 Carbon Dioxide Extraction

Carbon dioxide extraction uses carbon dioxide under extremely high pressure to extract
essential oils. Plants are placed in a stainless steel tank and, as carbon dioxide is injected
into the tank, pressure inside the tank builds. Under high pressure, the carbon dioxide
turns into a liquid and acts as a solvent to extract the essential oils from the plants. When
the pressure is decreased, the carbon dioxide returns to a gaseous state, leaving no residue
behind.
Many carbon dioxide extractions have fresher, cleaner, and crisper aromas than steam-
distilled essential oils, and they smell more similar to the living plants. Scientific studies
show that carbon dioxide extraction produces essential oils that are very potent and have
great therapeutic benefits. This extraction method uses lower temperatures than steam
distillation, making it gentler on the plants. It produces higher yields and makes some
materials, especially gums and resins, easier to handle. Many essential oils that can not
be extracted by steam distillation are obtainable with carbon dioxide extraction. In the
future, many botanicals that are not now available may possibly be obtained through
carbon dioxide extraction.
2.3 Cold pressing

Another method of extracting essential oils is cold pressed expression, or scarification.
It is used to obtain citrus fruit oils such as bergamot, grapefruit, lemon, lime, mandarin,
orange, and tangerine oils. In this process, fruit rolls over a trough with sharp projections
that penetrate the peel. This pierces the tiny pouches containing the essential oil. Then
the whole fruit is pressed to squeeze the juice from the pulp and to release the essential
oil from the pouches. The essential oil rises to the surface of the juice and is separated
from the juice by centrifugation.
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2.4 Solvent Extraction
Another method of extraction used on delicate plants is solvent extraction, which

yields a higher amount of essential oil at a lower cost. In this process, a chemical solvent
such as hexane is used to saturate the plant material and pull out the aromatic
compounds. This renders a substance called a concrete. The concrete can then be
dissolved in alcohol to remove the solvent. When the alcohol evaporates, an absolute
remains. Solvent extraction has disadvantages. Residues of the solvent may remain in the
absolute and can cause side effects.
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CHAPTER 3
DESIGN APPROACH
The first step in the design approach is to select the production method and the second
step is energy modeling to determine the amount of energy required to liberate the
essential oil from the plant material.
In addition, the experience from other developing countries (such as Haiti, Papua New
Guinea) and other essential oil distillation plants are considered in the design of the
plant.
3. 1 Production method selection

Among the different distillation methods discussed previously, steam distillation is
selected for the production of the essential oil. As the name suggests, steam distillation is
the process of distilling plant material with steam generated outside of the still in a steam
generator generally referred to as a boiler. A real advantage in using a boiler is that the
amount and pressure of steam can be controlled. In addition, Steam distillation gives
higher oil yield and since it is a faster process than other distillation methods so it is more
energy efficient.
An obvious drawback to steam distillation is that, the much higher capital expenditure
needed for the steam generator. The initial cost for the boiler is high and since the boiler
operates by electricity or petroleum, the running cost is high.
Hence, energy producing unit is a key component of steam distillation responsible for
the over all cost of the plant.
Taking this in to consideration, steam distillation is preferred by locally manufacture the

steam generator incorporating appropriate flow control valve, to control the flow rate and
pressure reducing valve to monitor the steam pressure and temperature. By doing so we
can have the same advantage as the commercial boiler.
14
This design can be applied for different type of plant material. As the oil liberating
energy is differ from plant to plant the amount of energy given is vary accordingly. This
variation can be made on the amount of pressure developed with in the still or boiler.
When the steam pressure developed contains enough amount of energy to liberate the oil,
reducing the pressure (keeping the enthalpy or amount of energy in the steam constant), it
can be possible to attain the pressure reduction as well as required amount of energy for
specific plant material
3.2 Energy modeling

The key point for energy modeling is modeling the property of the plant inside the still.
By assuming a given mass of plant material has some moisture inside it and considering
the oil yield of the plant material, the amount of energy required to liberate the essential
oil will be estimated, so that the amount of steam required will be known.
According to their local availability and their world, market class four aromatic plants are
selected and the calculation is performed based on the main components available in the
plant materials.
These plants are given as follows:
 Eucalyptus sp.(bahirzaf)
 Mentha spp. (nana)
 Cymbopogon citratus (lomisar)
 Cymbopogon sp. (tej sar)
3.2.1 Latent heat of vaporization of oil components
The latent heat of vaporization of oil components can be calculated by the following
equation;
 2.3Rd (log p)
L
d (1 / T )
Where L=molar latent heat (cals/gram mole)
R=gas constant (1.987 cals/K mole)
T=absolute temperature (oK)
P=vapor pressure
15
1) For Eucalyptus sp., by considering the basic component 1, 8-cineole (26.2%)
Temp.(oC) Temp.(oK) 1/T P(mmHg) Log P
85 358 2.79*10-3 9.82 0.99
99.3 372.3 2.69*10-3 19.1 1.28
110 383 2.61*10-3 30.35 1.48
Rearranging the formula, we have

 (1.48  0.99)

d (log P )
(2.79  2.61)  10 3
=-2722
d (1 / T )
 L=-2.3*1.987*-2722=12440 cal
12440 cal
Since mol. wt. of 1.8-cineole is 154, then its latent heat is = 80.8 cals per gram
154

kj
L=80.8*4.2=339.36
kg
2) For Mentha spp. by considering the basic component carvone (56.8%)
87 360 2.78*10-3 2.71 0.43
99.8 372.8 2.68*10-3 5.3 0.72
108 381 2.62*10-3 7.82 0.89
d (log P)  (0.89  0.43)

d (1 / T ) ( 2.78  2.62)  10 3
Then =-2875
L=-2.3*1.987*-2875=13139 cal
16
13139
Since mol. wt. of carvone is 150, then its latent heat is =87.6 cal per gram
150
 L=367.92
kj
kg
3) For Cymbopogon citrates, the basic component is citral (47.7%)
Then
86 359 2.79*10-3 4 0.60
99.7 372.7 2.68*10-3 8 0.90
108 381 2.62*10-3 12 1.08
d (log P)  (1.08  0.60)

d (1 / T ) ( 2.79  2.62) * 10 3
Then = =-2823.5
 L=-2.3*1.987*-2823.5=12903.7cal
Since the molecular weight of citral is 152, then the latent heat is
12903.7
=84.9 cal per gram
152

kj
L=356.58
kg
4) For Cymbopogon sp, the basic component is geraniol (78.5%)
87 360 2.78*10-3 2.9 0.46
99.8 372.8 2.68*10-3 5.8 0.76
108 381 2.62*10-3 8.7 0.94
Then
17
 (0.94  0.46)
  3000
d (log P )
d (1 / T ) (2.78  2.62) * 10 3
 L=-2.3*1.987*-3000=13710 cal
Since molecular weight of geraniol is 154, then the latent heat is
 89 Cal per gram

13710
154

kj
L= 373.8
kg
Then by considering these data, the amount of steam required to liberate the essential oil
can be calculated as follows:
Assumption:
Moisture content of the plant material = 55%-60%
Yield of Eucalyptus Citrodora
Max = 1.88%
Min = 0.66%
Specific heat capacity of plant material, C  0.85  3.57 o

cal kJ
o
g C kg C
Decisions:
Mass of the plant material in the still is, M= 50 kg
The pressure inside the steam generator is, P = 50 psi =0.34 Mpa
Density of plant material:
Considering three species of Eucalyptus
 For Eucalyptus ficifolia ,   0.33

g
cm 3
 For Eucalyptus globules,   0.42

g
cm 3
   0.45
g
For Eucalyptus Melliodora,
cm 3
Taking the average of the three species, we can estimate the density of the plant material
as follows:
18
 ave  0.4  400 3

g kg
3
cm m
From the above data, we can estimate the volume of the container for the plant material
V  , ………….. (From  
m

m
)
V
 V
50kg
=0.125 m3
kg
400 3
m
 V=125 L
Amount of water in the plant material (Mw)
Mw= moisture content (%)*mass of plant material (kg)
Mw= 60%*50 kg (considering the maximum moisture content of plant
material)
Mw=30Kg of water
Amount of Oil in the plant material (Moil)
w
Moil =Yield ( )*mass of plant material (kg)
w
=1.88 %*50 kg (considering the maximum oil yield)
Moil = 0.94 kg of oil
Latent heat of Vaporization of oil and water
By taking the maximum latent heat of vaporization of the oil
(i.e. oil from Cymbopogon sp.)
Loil =373.8 kj/kg
Then the amount of energy required to vaporize the oil is given by:
Eoil = Loil * Moil
=373.8 kj/kg*0.94 kg
Eoil= 351.372 kJ
To calculate the energy required to vaporize the water:
At one atm. Pressure, the latent heat of vaporization for water is
Lw = 2257.1 kj/kg
Then the amount of energy required to vaporize the water is:
Ewater = Lw* Mw
19
=2257.1 kj/kg*30 kg
Ewater =67713 kJ
Heat gained by the plant material

Heat gained by the plant material is given by
Hgained = C * M * T where: C-specific heat capacity
M-mass of plant material
T  T f  Ti
Tf -final temperature. =100 oC

Ti – initial temperature. = 20 oC
(Room temperature)
=3.57 *50*(100-20)
Hgained=14280 kJ
Then the total amount of energy required
Etotal = Eoil + Ewater + Hgained
=351.372 + 67713 + 14280
Etotal =82344.372 kJ
Amount of steam required
At pressure P =0.34 Mpa, and saturated temperature of 137.59 oC;
Enthalpy of saturated vapor, hg =2730.7 kJ/kg
Then the amount of steam required is given by:

E total 82344.372
Msteam =
hg 2730.7
Msteam =30.2 kg
Discussion:
By considering, some energy loses; the amount of water inside the steam generator (Mws)
is taken as;
Mws = 50 kg,
If it is assumed that 50 kg of water occupies 50 L by volume and 30 L for the steam
generated, then the total volume of the steam generator tank will be:
Vtank = 80 L
20
 The following data is obtained form essential oil distillation plant at wondo genet
The amount of plant material charged at one time

Mass of plant material = 300 kg
Volume of still = 2000L
Volume of water charged in boiler to generate steam during production
Volume of water in the boiler = 1000L
The duration of the whole distillation = about 2-3 hours
This data is important for comparing the theoretical result with the practical result during
an experimental distillation.
21
CHAPTER 4
DESTILATION PLANT DESIGN
The steam distillation process for the extraction of essential oils from plant material
consists of four basic parts:
 The steam generator or boiler
 Still or retort
 Condenser and
 Oil separator
4.1 Steam generators

There are numerous types of boilers that can be used as steam generators, some which are
heated vats(tanks) of water that generate saturated steam, while others are industrial
boilers that can be made of varying capacity and sophistication. The boiler for steam
distillation of essential oils should capable of producing a saturated steam at a pressure of
50 to 150 psi (i.e. 3.4 to 10.2 atm)
A way to determine how much steam is being generated from a homemade boiler or a
Commercially produced boiler is to measure it. This can be done simply by taking an oil
drum containing some water that has been tarred and then run the steam line into the
drum under the water to condense the steam for a set time. Taking care not to be burnt by
the steam or hot water, the weight of steam per unit time can be measured. From this
crude determination, the approximate capacity of the boiler can be determined.
22
Fig 4.1 schematic diagram of the steam generator

The steam generator mainly consists of the body, tank and the firebox (or combustion
chamber). The body is made from disused oil drum to reduce cost of production. And the
firebox is constructed inside the body using bricks, to insulate heat losses and keep the
temperature inside the combustion chamber higher even at very slow burning rate. The
fuel wood is loaded from the front through the fuel door and placed on the grate. The air
for combustion enters below the gate through an opening in the ash pit. To use the energy
from the burning fuel efficiently the hot gas is directed around the tank surfaces to get the
most heat from it then the smoke goes out through the flue.
4.2 steam generator mountings
These are the fittings, which are mounted on the steam generator for its proper and safe
functioning. Though there are many types of mountings, yet the following are important
for the distillation plant design.
o Pressure gauge
o Safety valve
o Flow control valve
o Pressure reducing valve
23
4.2.1 Pressure gauge

A pressure gauge is used to measure the pressure of the steam inside the steam
generator. The pressure gauge should be installed before the flow control valve. So that
the operator can read the amount of pressure inside the steam generator, before the steam
is allowed to flow. When the required pressure is reached, the flow control valve will be
opened and the steam will flow to the still through the pressure-reducing valve.
4.2.2 Safety valves
Safety valves are devices attached to a steam generator for preventing explosions due to
excessive internal pressure of the steam. In brief, the function of a safety valve is to blow
off the steam when the pressure of the steam inside the tank exceeds the working
pressure. In our case the steam generator tank is designed for working pressure of 0.34
Mpa, therefore the size of the safety valve should be determined based on this working
pressure and the size of the reinforcing ring in which the safety valve is to be fitted on the
steam generator. The designed reinforcing ring welded on the tank top has a size of ¾”.
4.2.3Flow control valves

Flow control valves are used to control the flow of liquids or gases, and they slightly
reduces the pressure in the system. In this design, the flow control valve is used to control
the flow of the steam from the steam generator to the still. A 3/4" globe valve can be used
for this purpose.
4.2.4 Pressure-reducing valves
Pressure-reducing valves provide a steady pressure into a system that operates at a

lower pressure than the supply system. A reducing valve can normally be set for any
desired downstream pressure within the design limits of the valve. Once the valve is
set, the reduced pressure will be maintained regardless of changes in supply
pressure (as long as the supply pressure is at least as high as the reduced pressure
desired) and regardless of the system load, providing the load does not exceed the
design capacity of the reducer.
24
Most pressure reducing valves currently available can be divided into the following two
main groups:
 Spring-loaded pressure-reducing valves (fig4.1)
 Pilot-operated pressure-reducing valves (fig 4.2)
Fig 4.1 Spring-loaded pressure-reducing valve
25
Fig.4.2 Pilot-operated pressure reducing valve
The main reason for reducing steam pressure is the steam generator is designed to work
at relatively high pressure than the still , about 0.34 Mpa, but the distillation must be
conducted under atmospheric pressure, as over oxidation are possible at high pressure.
Therefore, a pressure-reducing valve should be used between the steam generator and the
still to control the pressure. Moreover, since the temperature of saturated steam is closely
related to its pressure, control of pressure can be a simple but effective method of
providing accurate temperature control.
The pressure-reducing valve to be selected should satisfy the following specifications:
 Designed for low maintenance and easy to adjust

 High performance, heavy-duty design
 Sizes 3/4"
 Installs easily; common tubing (1/2”) is used to connect to desired point
downstream i.e. the still
 Pressure setting is infinitely adjustable from 0.34 Mpa to atmospheric
pressure
26
4.2 Still
The most critical parameter in the design of the still, or number of stills to be serviced is
the steam capacity of the boiler. If the amount of steam necessary to displace the oil, and
the oil content is known, then the size of the boiler should be able to be determined.
Plants are generally harvested over a short period of time when they have reached their
Maximum oil content so the amount of plant material that can be delivered to a distillery
is determinable. For most herbaceous materials containing superficial oils, a higher oil
yield will be obtained if the plant material is chopped into 2-5 cm pieces before it is
distilled; however, this is not necessary as this will take time, will require more labor
charges, and for the incremental increase in oil yield it may not be cost effective.
The still size can be designed, taking into consideration as to whether the oils present in
the Plant materials are superficial or subcutaneous oils and whether they are mainly
monoterpenoid in nature or whether they are rich in phenols, or alkenyl phenol ethers. As
a rule of thumb, if run under optimized conditions, steam distillation of 200-300 kg of
plant material containing monoterpenoid rich superficial oils will take between 15-20
minutes, whereas for the same quantity of plant material containing monoterpene-rich
subcutaneous oils the time will be increased. For the high boiling oils, the time taken to
isolate them will be directly proportional to the amount and pressure of the steam as well
as the height of the charge.
The still should be stainless steel in design. It should be easy to charge and discharge. To
easily discharge, the plant material from the still a basket made from a galvanized iron
wire mesh is used with in the still. In addition, the basket is placed on a stainless steel
perforated plate, which is supported by tubular legs that are welded to the plate.
27
The top of the still is covered by a lid then tightened by a metal band using bolt and nut.
To avoid any steam loss through the cover, the cover should be sealed by placing a
rubber on the realm of the drum before placing the lid. The most practical design for the
top of the still is either flat or a slight bulge. The use of the So-called gooseneck tops is
unnecessary with modern condensers. The tube from the still containing the vapor should
be connected to the condenser either by expansion tubing or preferably by a gasket bolted
with flat face connectors.
The stills should be properly insulated to reduce heat loss.
Fig. 4.3 Schematic diagram showing the still and the condenser
28
4.3 Separator
Once the oil and water vapors have condensed, the oil droplets must have time to
coalesce. This is done in the oil separator, a vessel that is also known as an oil-receiving
can or even a Florentine flask. Oils separate from water according to their density
because they are immiscible or only sparingly soluble. If their density is less than 1.00,
then they will float and are called “lighter than water” oils, whereas if their density is
greater than 1.00, then they will sink and are referred to as “heavier than water” oils.
Most of the oils from herbaceous plants and leaves are lighter than oils, while only a few
of the wood and root oils are heavier than water oils. Because of this difference, different
oil separators have to be used for the two types of oils. The two types of separators are
shown in figure 4.3
Fig 4.4 diagrammatic representation of the two kinds of oil separators
It is important that the oil separators should be large enough in volume to minimize
turbulence because significant amounts of oil can be lost with the distillate water if the oil
is not allowed to separate completely. It is recommended that the separator should be
large enough to take the equivalent of more than 4 minutes of distillate flow without
overflowing.
29
For oils that are lighter than water, the inlet for the water-oil emulsion should reach down
towards the bottom of the receiver, after which it should curve so that the oil-water
emulsion mixture enters the water in the separator with a slight swirling action. If the
inlet tube is made so that it can be raised, then the same separator can be used to collect
both oils, otherwise, a specific separator has to be made for the heavier than water oils.
Separation of oils whose density is very close to water or if one of the major components
of the oil has a density greater than 1.00, while all of the others have a density less than
1.00, is more difficult.
To complete separations of such oils, the temperature of the condensate must be

increased so that the temperature in the oil separator is sufficiently high for separation.
The optimum temperature for obtaining the best separation can be found by trial and
error. However, as the temperature in the separator increases, the density of the oil (and
its components) decreases. This decrease in oil density is far greater for the oil than it is
for water, so separation of hard to separate oils can be achieved if temperatures are of
50°C or more. To separate the oil from water, the temperature in the separator must be
maintained to give sufficient time for the oil droplets to either rise or sink. The increase
in temperature will reduce the density of the oil. It will also cause the viscosity of
condensate water to decrease more significantly than that of the oil, thereby removing
another barrier that could prevent minute oil particles from coalescing into droplets,
which will readily separate from water. Sometimes when separation of oil is difficult, the
distillate water is run back into the still (cohabitation) and redistilled.
30
4.5 Steam generator tank Design
 Volume of the tank

Known value:
V=80 L =0.08m3
 Optimum height & external diameter of the tank
H = 0.54m =540mm
De=0.44m=440mm
 Material used for the tank and the end plate is St 37

Decisions:
 Pressure inside the tank
 thickness of the sheet metal for construction of the shell is t= 3 mm

P=50 psi= 0.34 Mpa
Material Yield strength(  y )[Mpa] Ultimate strength(  u )[Mpa]

St 37 200 400
Find:
The minimum thickness of the cylindrical shell (ts) and thickness of the end plate (tp)
which resists the internal pressure
Cylindrical shell
The required thickens shall be calculated from the following equation
ts 
P * De
2f *z P
Where: z- weld joint coefficient (z =0.8)
f- Design stress (Mpa)
The design stress is given by
 y  
f =min  ; u 
1.5 2.4 
=min 133.33;166.7
 f =133.33 Mpa
Then the required thickens of the shell is
31
ts 
0.34 * 440
2 * 0.8 *133.33  0.34
=0.7mm
Discussion:
Since t = 3 mm > ts= 0.7 mm, a sheet metal with thickness of 3 mm is safe for the
construction of the cylindrical shell.
Flat end plate

Assumption:
The load is uniformly distributed on the plate
The minimum required thickness for the end plate is given by the following equation
t p  k1 * Di *
P
Where: k1 –constant (k1= 0.35 for fixed steel plate)
f
Di-inside diameter of the shell (Di= 434 mm)
For St 37
f = 133.33 Mpa
Then
t p  0.35 * 434 *
0.34
= 7.67 mm
133.33
Discussion:
The minimum required thickness for the end plate is tp=7.67 mm, but a standard sheet
metal thickness which is nearest to this value has thickness of 8 mm, therefore the end
plate thickness is taken as tp=8 mm.
For the end to be butt welded to the cylindrical shell, the flat end should be machined to
have a peripheral groove as shown in fig 4.5(a)
Fig 4.5 (a) grooved flat end butt-

welded to the shell
32
In addition; the required thickness tr at the bottom of the groove should be greater than or
equal to the shell thickens ts. i.e. t r  t s .
Design of openings
I. openings in shell
There are two openings in the cylindrical shell, the first is an opening for the steam
outlet and the second is for the water inlet.
Fig 4.5 (b), opening in the cylindrical shell reinforced by a reinforcing ring
Decisions:
A shell containing an opening shall be adequately reinforced in the area adjacent to the
opening. This is to compensate for the reduction of the pressure bearing section. The
reinforcement is given by using a reinforcing ring. (Fig4.5 (b))
''
3
The reinforcing ring is a pipe, with dimensions:
4
Internal diameter of the reinforcing ring, dir = 21mm
Width of the reinforcing ring, lr =2.87 mm
Thickness of the reinforcing ring, ear= 40 mm
A  A fr *  f s  0.5P  PAps  Apr 

The general equation for the reinforcement of an opening is given by:
fs
The stress loaded cross-sectional areas are given by:

A fs  ecs * l s
'
A fr  e r * l r
, and
The pressure loaded cross-sectional areas are given by:
33
A ps  As  0.5d * e a , s , where- As  ris * l s '0.5d 
A pr  0.5 * d i * er
Where: ecs- assumed shell thickness, ecs=2 mm

er- effective thickness of reinforcing ring, er= 9 mm
ea,s- analysis thickness of the shell wall, ea,s=3 mm
ls’- effective length of shell for opening reinforcement, ls’= 48.53 mm
ris- internal radius of the shell, ris=217 mm
d- diameter of the opening, d= 26.74 mm
fs- design stress of the shell material, 133.33 Mpa
P- Pressure inside the tank, P=0.34Mpa
For the reinforcement of an opening for the steam out let and the water inlet, the
stress loaded cross-sectional areas and the pressure loaded cross-sectional areas are
calculated as follows;
A fs  2 * 48.53  97.06mm 2
A fr  9 * 2.87  25.83mm 2
Apr  0.5 * 21* 9  94.5mm 2
Aps  13432.3  0.5 * 26.74 * 3  13472.41mm 2
A  A fr *  f s  0.5P  PAps  Apr 

Then from the equation of reinforcement
(97.06 +25.83)*(133.33-0.5*0.34)  0.34(13472.41+94.5)

fs
16364 N  4612.75 N
Discussion:
The reactive force provided by the material is greater than, the load from the internal
pressure, therefore the reinforcement is sufficient.
34
II. opening in the flat end

The opening in the end plate is for a relief valve and a set-on type nozzle
reinforces it. As shown in fig 4.5 (c)
Fig 4.5(c) opening reinforced by a set-on nozzle

''
3
The nozzle is made by a pipe,
4
Dimension: di=21 mm
eab = 2.87 mm
For a pierced circular flat end, the thickness of the flat end shall not be less than
that given below.
  P 
e  max  y1 * eo ;  c1 * y 2 * Di
 


  f 

Where eo is the calculated thickness of the un- pierced flat end, i.e. eo =7.67 mm
In addition, y1 & y2 are obtained as follows:
 j 
y1  min 2; 3  Eq 1
 jd 
y2 
j
jd
Eq 2
For single isolated openings

- d is the diameter of an opening or equivalent diameter of a nozzle
- j is equal to 2h for equation1 and Di for equation 2
When an opening has a nozzle, the equivalent diameter shall be given by:
35
d  di 
2A
,
A  l * eab  eb 
tp
l  0.8 d i  eb eb
Where: di-is the nozzle inside diameter

tp-the thickness of the end plate
A-is the nozzle reinforcement area
l-is the external length of a nozzle effective for reinforcement
eab-the thickness of the external section of a nozzle
eb-the thickness of the nozzle for pressure loading, eb=0.7 mm
l  0.8 21  0.7 * 0.7 =3.1 mm

A  3.12.87  0.7 =6.727 mm2
d  21
2 * 6.727
=19.32 mm
8
 
y1  min 2; 3 ,
434
 434  19.32 
j=2h= 434 mm
y1  min2;1, y1= 1
y2 
434
434  19.32
, j=Di= 434 mm
y2  1
Then;
  0.34 
e  max 7.67 *1;  0.39 *1 * 434
 
 , c1=0.39 from chart

  133.33 

e  max7.67;8.55
e  8.55mm
Since, e=8.55 mm > tp=8 mm, there is a need for additional reinforcement,
therefore the upper flat end plate is reinforced by a reinforcing ribs.
36
Ribs design
Fig 4.5 (d) flat end reinforced by a reinforcing ribs
The material for the rib is St 37 ( f  133.33Mpa )

Decisions:
The number of ribs (Z) is eight, i.e. Z = 8

The diameter of the flat end d = De = 440 mm
Find:
The dimensions of the rib
The design diameter of the head between the ribs do is given by:
 180 
d sin 
do   Z 
 180 
1  sin 
 Z 
440 * sin(180 / 8)
1  sin(180 / 8)
=
do = 121.8, then we assume D1 =122 mm

37
The design section modulus of cross section of the reinforcing ribs by assuming the
reinforcing ribs to be of rectangular cross section is given by:
Wr 
0.065d 3 * p
'
Z* f
0.065 * 4403 * 0.34
=
8 *133.33
Wr  1.765*103 mm3
'
We with the thickness to height ratio equal to 1:5,

Then the ribs design thickness is determined from
S r  0.62 * 3 Wr
'
=0.62 * 3 1.765 *103

S r  7.5mm , say 8 mm
 ),
Sr 1
Assuming the thickness to height ratio is equal to 1:5 (i.e.
h 5
Then, h = 5*Sr = 40 mm and a= Sr= 8 mm
38
4.6 Condenser design (shell and tube type)
As the name suggests the responsibility of the condenser is to change the phase of oil
and water vapor back into liquid so that as immiscible liquids they can be separated.
Some people refer to a condenser as a heat exchanger, which of course it is.
Usually a condenser is a tube or a series of tubes that are water cooled (below the
temperature of water vapor) so that the vapor emerging from the vapor tube will rapidly
change into the liquid phase. The reason water is used to cool the condenser is because it
is readily available and it absorbs the latent heat of condensation away from the hot
vapors allowing more of them to condense
The two main types of condensers are the multiple tube type or the coiled tube type. In
the past almost all condensers were designed as coiled tubular condensers which were
placed into some type of tank into which water was slowly added from the bottom to exit
at the top. These tubular condensers were set lower than the still tops so that no
condensation would occur above the still and cause any run back into the top of the still.
Because the coiled tubular condenser was narrower than the vapor tube exiting the still
top, there was a backpressure build-up in the condenser. This backpressure build-up was
the reason why gooseneck still heads (tops) were designed so that there was a pressure
equalizer before the hot vapors entered the tubular condenser.
Since the multiple tube condensers, sometimes known as shell and tube condensers,
have been designed there has been no need to build in the pressure equalizing still head.
This has led to the design of flat or slightly curved still tops are the normally designed
still tops with the multiple tube condensers. The main differences between the two
condensers can be summarized as follows:
39
Coiled Tubular Condenser Multiple Tube Condenser

Easy to make Difficult to make
All metal types used Stainless steel
Poor heat transfer Good heat transfer
High pressure build-up during distillation No pressure build-up during distillation
Needs tank of water with sparse use of Needs running water

running water
Non-economical use of water Economical use of water
The temperature of the water in the condenser has a direct relationship on the ability
of the condenser to dissipate the heat from the oil and water vapor, thereby allowing rapid
condensation. However, it does not necessarily follow that condensed oil will separate
more easily from a cold condensate water
40
Components of the Condenser
4.1.1Shell
Shells are generally made from standard wall steel pipes. Shells of greater diameter are
fabricated by rolling steel plate and then welding. The thickness of the shell wall is
strictly dependent on the working pressure of the condenser, which is assumed to
constant throughout the condenser.
4.1.2Tubes
Heat exchanger tubes are also referred to as condenser tubes. The outside diameter of
heat exchange tube is the actual outside diameter in inches with in a very strict tolerance.
Heat exchanger tubes are available in a variety of metals. They are also obtained in a
number of different wall thickness defined by the Birmingham wire gauge which is
usually referred to as the BWG. The most common sizes of tubes in heat exchanger are
3 4 in. OD and one in. OD. The tubes are fixed to tube sheets to form tube bundles. The
sheets, baffles, support plates, tie rods and usually spacers complete the bundle.
4.1.3 Baffles Tie Roads and Spacers
To introduce outside the tubes usually baffles are provided, which the liquid to flow
through the shell at right angle to the axes of the tubes. This causes considerable
turbulence even when a small quantity of liquid flow through the shell.
Baffle spacers are used to hold the baffles securely. The most common types of baffles
in heat exchanger are segmental baffles. Segmental baffles are drilled plates with heights,
which are generally 75 percent of the inside diameter of the shell and these are also
known as 25 percent cut baffles.
Tie rods are used to hold the baffles in place with the spacers, which are pieces of tubing
or pipe placed on the rods to locate the baffles.
41
In our case:
The steam containing essential oil vapor leaves the still and passes into a condenser by
way of tube. Some sort of gauze or screen is often fitted at the mouth of the tube to
prevent plant material being blown over into the condenser. In the condenser, the vapors
are cooled and condense. It is important that condensation is complete or oil may be lost
by evaporation. A more efficient type of condenser is the multi-tubular type in which a
series of parallel tubes are mounted inside a cylindrical jacket through which cooling
water is passed. This design provides a large surface area for cooling in relation to its
volume. The mixture of water and essential oil leaves the condenser and flows into a
separator in which they separate into two layers.
The fluid property, temperature, fluid flow rates and the preliminary estimates of the size
of the condenser are employed to determine the appropriate heat transfer coefficient.
In the design of the condenser, the process is evaluated at film temperature.
Tin  Tout
Where Tf= 2
Where Tin and Tout are inlet and outlet temperature of the refrigerant.
Assumptions and observations
1. Flow to the shell
I. volume flow rate is

Q=V*A Where; Q = volume flow rate
A= cross sectional area
V = speed of fluid
m =  VdA
II. mass flow rate ( m ) of the fluid is
Where;  =density of the fluid
.
V = speed of fluid
A= cross sectional area
Assumption and selection

42
Fig 4.6 water contain thank elevation
Let the thank height to be 1.2m

Then the energy balance equation for the fluid flowing through the pipe is given by
p1  1v1 p2  2 v2
  Z1    Z 2 ------- --for the points 1 and 2
2 2
 2g  2g
Where p1 &p2 = pressure at point 1&2
Z1 & Z2 = relative position of point 1&2
 1 &  2 = are discharge coefficients and taken to be 1

V1& V2 = velocity of fluid at point 1&2
 no pressure difference (p1=p2)

However, for our case we can assume that:
 v1=0 at the surface point

 Z2=0 at reference of base
Then equation becomes

2
V
0+0+1.2=0+ 2 +0
2g
V2= 2 * 9.81*1.2
= 4.85 m s
To obtain the mass and volume flow rates select standard pipe size according to BWG
Nominal pipe size = 3 4
ID =0.824in=20.9mm
OD=1.05in=26.67mm
Then volume flow rate:
Q=V.A
43
 * id 2
Where, A=
4 3
=1.6*103 m sec
Mass flow rate:
m = VA , density of water is taken to be 1000 Kg m3
.
=1.664 Kg sec
2. Flow inside tube
The recommended speed of steam in pipelines is 80 ft sec (24.5 m sec )
Then the mass flow rate:
m = VA
.
Where:  = saturated gas density at 1000c

V=steam speed
A= cross-sectional area
Then select the pipe size and dimension from standard
Fig 4.7 condenser
Where D=diameter for shell

D´=diameter for steam to come
Tube size 1 2 in OD tubes on 1 in – square pitch
44
OD= 1 2 in=12.7mm
T=0.109in=2.77mm
ID=0.282in=7.16mm
Fig 4.8 tube dimensions
Total number of tubes taken is to be 20.
D 2 D '2
Then tube for steam to come with the same speed is if it is one tube
*n  Where; n=number of tubes

4 4
D1= tube diameter
D´=main tube diameter*-
D´=D1 n
=32mm
Standard steel pipe for this size is
Nominal pipe size=1 1 4 in
OD=1.66in=42.16mm
ID=1.380in=35mm
Then
m = VA , but density of saturated gas at 1000c as if it is pure water is
.
  0.6 kg m 3
V=15 m sec
m = 0.6 * 24.5 *  *
. 7.162
4
= 0.0117 kg sec
Another available and assumed data’s
45
 Saturated steam enters to condenser at 1000c (T1).

 Saturated steam leaves the condenser at 600c (T2).
 Cooling water is at room temperature at 220c (t1).
Energy and thermal balance
Since the steam is saturated gas, it has latent heat of condensation and sensible heat
rejection
.
Q v =L* m
Where L= latent heat of vaporization (2257 kj kg )
.
m =mass flow rate ( kg sec )
Then amount of heat rejected during condensation is
Q v =2257 kj kg *0.0117 Kg sec
=26.4kw
Sensible heat reduction

. .
Qs= m c Δt where; m =mass flow rate
C= specific heat capacity of hot fluid
ΔT= tf - ti
=0.0117*4.179*(40)
= 1.96kw
Then the total amount of heat energy released is

Qt= Q v + Q s
=28.5kw
Then from thermal balance

Amount of heat released by steam= Amount of heat absorbed by cold water
Q steam=Q water
Q v +Q s= Q w
. .
28.5kw= m cΔT where: m = mass flow rate of cold water
46
C =specific heat capacity of water at mean temperature

28.5kw
ΔT=
1.664 * 4.183
= 40c
ΔT = Tf –Ti;
Then Tf=26.01oc
22  26.01
The raw water is heated at this temperature
Then the mean temperature Tm =
2
=24.0 0c
  9.1 *104 kg ms
Property of water at mean temperature
k= 0.610 w m o c
Pr=6.20
Shell side
Log mean temperature
T1  T2
ln T1 T2
LMTD=
Where; T1 = (T1-t2)
T2  (T2  t 2 )
LMTD=53.40c
Fig4.9 shell cross section
47
Assumptions:
Baffle spacing to be 70mm (with in 1 5 th and in side shell diameter) and are 16 in
number
Shell inside diameter ID =203.2mm and thickness of 2 mm
I. Mass velocity
Factious mass velocity is given by

.
m .
Gs = where m = mass flow rate ( kg sec )
as
as =equivalent flow area
ID * c ' * B
as= where B=is baffle spacing
PT
c’=PT-od
PT=tube center to center distance

as=3048*10 6 m2
1.66 * 106
Gs=
3048
=545.93 kg sm2
II. Reynolds number to check the flow is laminar or turbulent
where;  =dynamic viscosity of water at film temperature


G s * De
Rs=
De=equivalent flow diameter

4 * flow' area
=
wetted' perimeter
4 * ( PT 2 *  * id 2 4
do
=
= 52.2 mm
Rs=3191.6 hence Rs  2300 the flow inside the tube is turbulent
For turbulent flow, we use the fowling relationship
48
hDe
Nu= = 0.0241Rs .8 Pr n Where Nu= is nulsent number
k
n=0.3 for cooling
n=0.4 for heating
In our case n=0.4 because cold water is heating
Substituting the values for Rs and Pr
Nu=200
200 * 0.62
53.2 *103
ho=
= 2337 w m 2 out side heat transfer rate
Tube side
I. Mass velocity
Mass velocity in tube side is given by

.
m
Gt= ; where At =total flow area
At
 * id 2
At=no of tubes *
 * 7.16
4
2
=32* =1.28m2
4
0.0117
Then Gt=
1.28
=9.14 kg ms
II. Reynolds number to check the flow is laminar or turbulent

Gs * dh
Rt= , where dh= is hydraulic diameter which is equal to id.
100  60
The mean temperature is =80.0oc
2
 = 3.47 *104 kg / ms
Property if water at mean temperature is
(dynamic viscosity)
K=0.670 w mk w m o c (thermal conductivity)
Pr=2.08 (prandtl number)
49
9.14 * 7.16 *103

3.47 *10.4
Then Rt=
=18.86  2300
Hence, the flow inside the tube is laminar, for laminar case, we can use the
following relationship:
 g * k 3 * h ' fg  4
hi=0.555  1 ( 1   v )
1
  * id (t s  t w ) 
Where; 1 ,  v density at mean temperature for fluid and vapor

g=gravitational acceleration
k= thermal conductivity
  4.3 *10 4
id =internal diameter
h’fg=hfg+ 3 8cp t s  t w  where; ts =mean temperature

tw =wall temperature where approximately little less
than ts, assume is 100c less than ts
hfg =latent heat of water at 800c
Cp=4.196 kj kg 0 c 
At mean temperature 80.00c the property of fluid is
hfg =2308 kj kg
Then h’fg=2308+ 3 8 (4.196)(10)
=2324.01 kj kg
Then hi=12533 w m 2 k
id
hio = hi
od
7.14
=12533*
12.7
=7065.3 w m 2 k
Then the clean over all heat transfer coefficient

h *h
hio  ho
Uc = io o
7065.3 * 2337
7065.3  2337
=
=1756.0 w m 2 k
Then dirty factor for resistance is taken to be Rf =0.0003 for city water
50
Finally the designed over all heat transfer coefficient is Ud is calculated as

 Rf 
1 1
Ud Uc
Ud =1150.01 w m 2 k
We know that:
Q=Ud A ( Tm ) lm where; ( Tm ) lm is log mean temperature

Q
U d Tm
The area then; A=
28.4 *103
=
1150* 53.3
Then the total surface area will be A=n*  * id * L

=0.465m2
n *  * id
A
The length of the tubes is obtained as L=
20 *  * 7.16
0.465
=
=1.03m of tube length is required
51
CHAPTER 5
MATERIAL AND COST ESTIMATION
The materials used for the design of the distillation plant are selected considering
- their local availability
- low cost and
- their effect on the oil quality
To have high quality oils; the still, condenser and separator should be constructed using
stainless steel , because other materials like iron , copper and aluminum react with
essential oils and affect the quality of the oil.
The materials required for the construction of the distillation plant and the available
material cost is summarized in the following table:
Material Dimension Quantity Cost Note

(birr)
Oil drum 55 gallon 1 150 The oil drum is used to
contract the body of the
 20
steam generator
Structural steel 1 235 The structural steel is used
L= 1200 as the steam generator tank
support and for the
3 1000 2000
construction of the grate
8 1000 2000
Sheet metal 380 The sheet metal is St-37, and
2000 it is used for making the
0.8 1000 2000

steam generator tank
Sheet metal The sheet metal is stainless
steel, for the still, condenser
shell and for the construction
of the oil separator
Pipe 1/2", L= 6000 1 55 The pipe is galvanized steel
pipe
Pipe 1/2”, Stainless steel pipe to be
welded inside the still for the
steam passage and pipes for
the oil separator
52
Pipe 1/2" , L=4800 6 Stainless steel condenser

pipes, used for the condenser
Reinforcing 3/4” 4 A standard 3/4" pipe
ring coupling can be used as the
reinforcing ring
Elbow 3/4” 4
Galvanized 1 It is used for the construction
welded iron of the basket inside the still
wire mesh
3  40  6000
Perforated plate
Angle iron 1 Used as a support for the
steam generator, still,
condenser and oil separator
Pressure
control valve
Pressure relief
valve
Flow control A standard globe valve can
valve be used as the flow control
60 125 250
valve
Brick
Metal band
Sack and cotton Used as an insulation
materials for the still & pipes
53
Conclusion
Essential oils play a great role in the economic development of a country because
establishment of essential oil industry is the gateway to an endless variety of other
industrial transformation. The industries require a reliable supply of high quality oils.
This project targets to produce a distillation plant with low cost. Therefore, the design is
tied with optimization of the technology to produce high quality oil and the cost of the
 Steam distillation gives high quality oil, because the amount and pressure of the
distillation plant. Considering this, we can conclude that:
 The initial and running cost for a commercial boiler is high; this implies that the
steam from the steam generator can be controlled
energy production unit (steam generator) takes much of the cost of the distillation
 In this design a locally manufactured, low-cost steam generator, maintaining the

plant.
advantages of the commercial boiler, substitutes the boiler. Therefore the overall cost
 In addition, the cost of the distillation plant can be reduced by using energy
of the distillation plant is significantly lowered
efficiently. From the energy modeling it is found that much of the energy given to
liberate the essential oil from the plant material is taken by the moisture inside the
plant .Therefore it is important to know the optimum moisture content of the plant
 Moreover, to have high quality oil, the still, condenser and separator should be
before the distillation process.
constructed by stainless steel. Because other materials like iron, copper and aluminum
react with essential oil and affect the quality of the oil.
54
Recommendation
 It is clearly seen that the overall cost for the distillation plant can be reduced by using
energy efficiently. Since wood is least sustainable energy source; it is recommended
to use other low cost fuel like rubber, trashes and chips from woodwork shops as a
source of energy. In addition, it is possible to incorporate a solar water heater in to the
 To reduce heat loss from the pipes and the body of the still, insulation is very
system to preheat the water before it enters the steam generator.
important. To reduce the cost of insulation, insulation made from locally available
 To have good quality oil from a distillation, the duration of the whole distillation
materials like sacks and cotton can be used.
should be known, because prolonged distillation produces only a small amount of

extra oil, but does add unwanted high boiling compounds and oxidation products. The
time that it takes to distill a given amount of plant material cannot be calculated from
theory; therefore, it must be determined by running some trial distillations.
 Separation of oil whose density is very close to water or one of the major components
of the oil has a density greater than one while all of the others have a density less than
one is more difficult. To avoid such problem the temperature of the condensate must
be maintained above 500c.
 The distillery site should have the following requirements

 ample availability of water
 closed proximity to the plant material that will be distilled
55
Bibliography
1. http://www.itdg.org/docs/technical_ information_service/essential_oils.pdf
2. http://www.crop.cri.nz/home/products
services/publications/broadsheets/039essentialoils.pdf
(ESSENTIAL OIL AND THEIR PRODUCTION)
3. http://www.oneplanetnatural.com/stores/oneplanet/distillation.htm
(THE EXTRACTION OF ESSENTIAL OILS)
4. http://www.ccnphawaii.com/distillation.htm
(STEAM DISTILLATION METHOD)
5. http://www.naturesgift.com/extraction.htm
(METHODS OF DISTILLATION)
6. http://ejournal.sinica.edu.tw/bbas/content/2005/2/Bot462-05.html
(LEAF CHEMICAL PROPERTY)
7. K. tuley de Silva. MANUAL ON ESSENTIAL OIL INDUSTRY,

1995, Austria Vienna
8.. J.P Holman. HEAT TRANSFER. 8th ed. Mc Graw Hill, 1997, New York.
9. Donald Q.Kern. PROCESS HEAT TRANSFER. 2nd .1990. Mc Graw Hill, New York.
10. Pressure vessel design “European standard EN13445”

11. David S. Azbel, Nicholas P.cheremisinoff. Chemical and process equipment design,
vessel design and selection, 1986
56

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Essential oil distillation plant project

In general, there are four types of extraction methods:

 Carbon dioxide extraction

 Cold pressing and

These extraction methods will be briefly discussed in the next chapter.

 direct culinary use: as fresh or dried herbs, spices and condiments;

 In perfumery, cosmetics, and household and personal hygiene products either

 In food, and drink: as flavoring agents;

 In human and veterinary medicine: as components of pharmaceutical

 In crop protection: as pesticides and insect repellents; and

 As antibacterial and antifungal agents in a range of situations.

1.2 Industrial use of essential oils

Cosmetics and toiletries:

Medical & Veterinary

Rubber & plastics

1.3 Ethiopian essential oils

Botanic name Amharic Family Yield Availability Commercial use

Foeniculum Ensilal Apiaceae 0.14% Addis Ababa, Food flavoring, in liqueur,

There are three basic types of essential oil distillation:

i. water distillation or "hydro distillation"

ii. water and steam distillation or "wet steam"

iii. steam distillation or "dry steam"

2.1.1 Water Distillation

 Oxygenated components such as phenols have a tendency to partially dissolve in

 As water distillations tend to be small (being operated by one or two people), it

2.1.2 Water and steam Distillation

2.1.3 Steam Distillation

Figure 2.1.3 Diagrammatic representation of steam distillation unit

The advantages and disadvantages of steam distillation are as follows:

2.2 Carbon Dioxide Extraction

2.3 Cold pressing

2.4 Solvent Extraction

Another method of extraction used on delicate plants is solvent extraction, which

3. 1 Production method selection

Taking this in to consideration, steam distillation is preferred by locally manufacture the

3.2 Energy modeling

These plants are given as follows:

1) For Eucalyptus sp., by considering the basic component 1, 8-cineole (26.2%)

Temp.(oC) Temp.(oK) 1/T P(mmHg) Log P

85 358 2.79*10-3 9.82 0.99

99.3 372.3 2.69*10-3 19.1 1.28

110 383 2.61*10-3 30.35 1.48

Rearranging the formula, we have

Temp.(oC) Temp.(oK) 1/T P(mmHg) Log P

87 360 2.78*10-3 2.71 0.43

99.8 372.8 2.68*10-3 5.3 0.72

108 381 2.62*10-3 7.82 0.89

d (log P)  (0.89  0.43)

Temp.(oC) Temp.(oK) 1/T P(mmHg) Log P

86 359 2.79*10-3 4 0.60

99.7 372.7 2.68*10-3 8 0.90

108 381 2.62*10-3 12 1.08

d (log P)  (1.08  0.60)

Temp.(oC) Temp.(oK) 1/T P(mmHg) Log P

87 360 2.78*10-3 2.9 0.46

99.8 372.8 2.68*10-3 5.8 0.76

108 381 2.62*10-3 8.7 0.94

(97.06 +25.83)(133.33-0.50.34)  0.34(13472.41+94.5)