“REFINING OF RICE- BRAN WAX ”

A PROJECT REPORT

Submitted by

ASHUTOSH SHUKLA (190111010)

SHUBHAM KUMAR YADAV (190111030)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in

OIL TECHNOLOGY

HARCOURT BUTLER TECHNICAL UNIVERSITY

KANPUR- 208002 , UTTAR PRADESH
 CERTIFICATE

Certified that this project report on “ REFINING RICE BRAN

WAX is the work of “ASHUTOSH SHUKLA, SHUBHAM
KUMAR YADAV ” who carried out the project work under my
supervision.

SIGNATURE

GAURAV SINGH (supervisor)

Assistant Professor
Oil Technology
Harcourt Butler Technical
University
Kanpur - 208002

ACKNOWLEDGEMENT
We express our deepest gratitude to our Dr. PRAVEEN KUMAR SINGH
YADAV HOD, oil Technology for providing us with an environment to
complete our project successfully. We would like to thank him for the
unwavering support during the entire course of the project work who modeled
us both technically and morally for achieving greater success in this project
work.

We express our sincere thanks to our Supervisor Mr. GAURAV SINGH

Assistant Professor, Department of Oil Technology for his constant
encouragement and support throughout our course, especially for the useful
suggestions given during the course of the project period and being instrumental
in the completion of our project with his complete guidance. We thank
ourProject supervisor for his help and innovative ideas in making this project a
successful one.

We are greatly indebted to our honorable Dr. VINEETA GAUTAM for our
motivation and support.

We are very grateful to Dr. R.K TRIVEDI for her valuable guidance and
blessings.

We also thank Mr. H.S SHARMA ,Mr. P.C GUPTA and Mr. SAMEER
SINGH Department of Oil Technology for their assistance in completing the
fabrication work.

Finally, we take this opportunity to extend our deep appreciation to our family
and friends for all that they meant to us during the crucial times of the
completion of our project.

CONTENTS
A. LITERATURE
1.Introduction to rice bran wax
2.Market review of rice bran wax
3.Physico-chemical property of
rice-bran wax
4.Extraction of rice bran wax
5.Purification of rice bran wax.
6. Function of rice bran wax.
B. EQUIPMENT DESIGN
1.Introduction
2.Plate Heat Exchanger
C. TECHNO-ECONOMIC
FEASIABILITY REPORT
1.Information and particulars of
project
2.Total cost of project
3. Depreciation of project
4. Insurance
5.Dept Equity ratio
6. Break Even Point
7.Brief Particular of the Project
8. Cost of production and
Profitability Statement
9. References

INTRODUCTION
 It is rich in antioxidants (vitamin C, total phenolsand carotenoids) and
appreciated by consumers for its nutritional value, sweet taste and
pleasant aroma .In many countries, fresh cherry tomatoesplay an
important role in produce markets. However, considerable amounts of
cherry tomatoes are spoiled during fruitgrowth and postharvest. These
food losses are due to the diverse regional climates and undeveloped cold
chain transportation, especially in some areas.
Storage technologies have been developed to extend the
shelf life of cherry tomatoes. For example, combined treatment of heat
and modified atmosphere packaging delayedthe color development of
cherry tomatoes.
Controlled atmosphere storage and modified atmosphere
packaging and edible coating improved the postharvest quality and shelf
life of fruits .
In addition, a complex coating (0.05% kon-jak powder, 0.05%
sodium alginate and 0.02% ascorbic acid) reduced the decay
rate of cherry tomatoes during cold storage.
However, cassia oil, magnesium sulphate or their combination
did not affect the quality of cherry tomatoes.In recent years, wax coating
has been widely used as acoating agent for preserving fruits and
vegetables. The edible coating is considered as one of the most-effective
and safer ways to prolong the shelf-stability of the horticultural crops.
Utilization of rice bran wax (RBW) as a coating substrate can be an
excellent shelf-life extension strategy by transforming secondary by-
product from rice processing into a useful coating substrate. This research
was an attempt to use RBW as an edible coating and its effects on the
shelf-life extension of CO3 variety tomatoes. Crude RBW refined in
laboratory-scale was undergone for free fatty acid profile analysis and
found that contains 18 health-beneficial free fatty acids. RBW was made
into an emulsion with different concentrationsused for coating the
tomatoes. Physiological loss weight, lycopene content, TSS, firmness,
respiration rate, SEM structure, and thickness of the coatings were
analyzed and observed that 10% emulsion coated tomatoes had shown a
shelf-life of 27 days, compared to 18 days of the control samples.
Rice (Oryza sativa) is one of the most important grains in the world. India
is second largest producer of Rice in the world. The outer covering of rice
kernel after removing the husk is called Rice bran. It is valuable
byproduct of rice milling industry because it contains 12-25 % of oil
depending on quality1 . The oil extracted from Rice bran is called Rice
bran oil and is available in both grades (i.e. edible and non edible). Rice
bran wax is hard non tacky wax and is the byproduct of Rice bran oil
refinery. Its presence is 2-5 % in Rice bran oil. It is recovered as sludge
wax and further processed to slack wax, pressed wax. This form is
solvent extracted to produce pure wax which is further refined and
bleached to procure hard wax of food or cosmetic grade. It is white to
yellowish in color and can be made available in flakes form also10. The
chemical constituents of Rice bran wax are mainly saturated monoesters
(C-46 to C-60) of long chain fatty acids (C-22 to C-26) and long chain
fatty alcohols (C-26 to C-30). Main esters are myricyl cerotate (43-45 %),
ceryl cerotate (21-22 %) and Isoceryl isocerotate (9-10 %). The refined
and bleached Rice bran wax has melting point78-82°c, Saponification
value 70-120 and iodine value 4 to 10. It can be used in many industries
like polishes, leather, crayons, candle making, shoe creams, paper
coating, carbon paper, lubricants etc. Its major consumption is in food
industries as constituents of chocolate enrobers, vegetable coating, and
wax emulsion for fruit preservation. Recently lot of research work is done
on Rice bran wax for its use in pharmaceutical and cosmetics products. It
has chemical constituents and physicochemical properties similar to that
of Carnauba wax which is drawing interest of researchers for using this
wax in various pharmaceutical products like tablets, ointment bases,
suppositories and cosmetic products like moisturizing lotions, lipsticks,
creams etc. Lots of work is done in USA, China and Japan but most of
those are patented. It can also be used in Novel Drug Delivery Systems
(NDDS) which is currently hot research and development area of
pharmaceutical industries.

MARKET REVIEW OF RICE BRAN WAX

According to a report published by Transparency Market Research, the
global rice bran wax market was valued at USD 112.1 million in 2020
and is expected to reach USD 146.9 million by 2028, growing at a CAGR
of 3.4% from 2021 to 2028. The report also highlights the increasing
demand for natural and organic products in various industries as one of
the key drivers of the market growth.
Another report by Zion Market Research estimates that the global rice
bran wax market will reach USD 171.6 million by 2025, growing at a
CAGR of 3.6% from 2019 to 2025. The report identifies the cosmetics
and food industries as the major end-users of rice bran wax, with the
cosmetics industry accounting for the largest share of the market.
Overall, the market for rice bran wax is expected to grow steadily in the
coming years, driven by the increasing demand for natural and organic
products in various industries.The Global Rice Bran Wax market is
anticipated to rise at a considerable rate during the forecast period,
between 2023 and 2030. In 2021, the market is growing at a steady
rate and with the rising adoption of strategies by key players, the
market is expected to rise over the projected horizon.
As the global economy mends, the 2021 growth of Rice Bran Wax will
have significant change from previous year. According to our Researcher
latest study, the global Rice Bran Wax market size is USD million in
2022 from USD million in 2021, with a change of percent between 2021
and 2022. The global Rice Bran Wax market size will reach USD million
in 2030, growing at a CAGR of percent over the analysis period.

The United States Rice Bran Wax market is expected at value of USD
million in 2021 and grow at approximately percent CAGR during review
period. China constitutes a percent market for the global Rice Bran Wax
market, reaching USD million by the year 2030. As for the Europe Rice
Bran Wax landscape, Germany is projected to reach USD million by
2030 trailing a CAGR of percent over the forecast period.
Physio-Chemical property of rice bran wax
Rice bran wax is a natural wax obtained from the outer layer of rice
grains. It has several physio-chemical properties, including:
1. Melting point: The melting point of rice bran wax is around 78-
85°C, which is relatively low compared to other waxes.
2. Acid value: The acid value of rice bran wax is approximately 10-25,
indicating that it contains a significant amount of free fatty acids.
3. Saponification value: The saponification value of rice bran wax is
around 85-105, which is lower than other vegetable waxes.
4. Ester value: The ester value of rice bran wax is around 70-90,
indicating that it contains a high amount of esters.
5. Color: Rice bran wax is typically light yellow to brown in color.
6. Odor: Rice bran wax has a faint odor, which is not considered
unpleasant.
7. Solubility: Rice bran wax is insoluble in water but is soluble in
organic solvents such as ethanol, ether, chloroform, and benzene.
8. Density: The density of rice bran wax is approximately 0.98-1.02
g/cm3.
Overall, rice bran wax is a versatile natural wax with several physio-
chemical properties that make it suitable for use in various industries,
including cosmetics, food, and pharmaceuticals.
Melting Point
Dried a small quantity of the finely powdered RBW at a temperature
considerably below its melting point. a portion to a dry capillary tube
and packed the powder by tapping on a hard surface so as to form a
tightly packed column 4 to 6 mm in height. Attached one of the tubes to a
thermometer graduated in 0.5°C so that the substance is close to the bulb
of the thermometer. Introduced the thermometer with the attached tube
into a beaker so that the distance between the bottom of the beaker and
the lower part of the bulb of the thermometer is 1 cm. fill the beaker with
water to a depth of 5cm. Increased the temperature of the water gradually
at a rate of 1 c/min. The temperature at which the substance begins to rise
in the capillary tube was regarded as the melting point. Repeated the
operation with the other 4 capillary tubes and calculated the result as the
mean of the 5 readings.
Specific Gravity
Selected a scrupulously clean, dry pycnometer that previously has been
calibrated by determining its weight and the weight of recently boiled
water contained in it at 25°C. Melted the substance and filled the
pycnometer with it. Adjusted the temperature of filled pycnometer to
25°C and weighed. Subtracted the tare weight of the pycnometer from
the filled weight. The specific gravity is the quotient obtained by dividing
the weight of sample contained in the pycnometer by the weight of water
contained in it, both determined at 25°C.
Moisture Content
Standardization of the reagent Placed about 36 ml of dehydrated
methanol in the titration vessel and added sufficient KF reagent to give
the characteristic end-point. Added quickly 150 to 350 mg of sodium
tartrate accurately weight by difference and titrated to end-point. The
water equivalence factor F in mg of water per ml of reagent is given by
the formula.

Saponification Value
Weighed 2 g of the RBW into a 200 ml flask, added 40.0 ml of the
ethanolic solution of potassium hydroxide and boiled under a reflux
condenser for 2 hour, rotating the contents frequently. While the solution
was hot, titrated the excess of alkali with 0.5 M hydrochloric acid using
phenolphthalein solution as indicaor. Repeated the operation without
RBW. Calculated the Saponification Value from the expression 28.05
v/w where v is the difference, in ml, between the titrations and w is the
weight, in g, of substance taken.

Acid Value
Dissolved 10.00 g of RBW in 50 ml a mixture of equal volumes of
ethanol (96 %) and light petroleum, previously neutralized with 0.1 M
sodium hydroxide, using 0.5 ml of phenolphthalein solution as indicator.
Heated to about 90°C to dissolved the RBW. When the substance has
dissolved, titrated with 0.1 M sodium hydroxide until the pink color
persists for at least 15s (n ml of titrant). When heating has been applied
to aid dissolution, maintained the temperature at about 90°C during the
titration

Ester Value
The ester value was calculated by following formula;

Hydroxyl Value
Introduced 2.0 gm of RBW into a 150 ml acetylating flask fitted with an
air condenser. Added 5 ml of acetic anhydride solution and attached the
air condenser. Heated the flask in a water- bath for 1 h keeping the level
of the water about 2.5 cm above the level of the liquid in the flask.
Withdrawn the flask and allowed it to cool. Added 5 ml of water trough
the upper end of the condenser. Added sufficient pyridine to clear
cloudiness and the volume added was noted. Shaken the flask and
replaced it in the water- bath for 10 min. Withdrawn the flask again and
allowed to cool. Rinsed the condenser and the walls of the flask with 5
ml of alcohol, previously neutralized to phenolphthalein
solution .Titrated with 0.5 M alcoholic potassium hydroxide using 0.2 ml
of phenolphthalein solution as indicator (n2 ml of 0.5 M alcoholic
potassium hydroxide). Carried out a blank test under the same
conditions (n2 ml of 0.5 M alcoholic potassium hydroxide).
Unsaponifiable Matter

To 2.0 to 2.5 g of RBW contained in a 250 ml flask, added 25 ml of 0.5

M ethanolic potassium hydroxide and boiled under a reflux condenser in
a water - bath for 1 hour, swirling the contents frequently.Washed the
contents of the flask into a separating funnel with the aid of 50 ml of
water and while the liquid was slightly warm, extracted by shaking
vigorously with three 50 ml quantities of peroxide free ether, rinsing the
flask with the first quantity of ether. Mixed the ether solutions in a
separating funnel containing 20 ml of water. Gently rotated separating
funnel for a few minutes without violent shaking, allowed the liquids to
separate and discarded the aqueous layer. Washed the ether solution by
shaking vigorously with two 20 ml quantities of water and then treated
with three 20 ml quantities of 0.5 M potassium hydroxide, shaking
vigorously on each occasion, each treatment was followed by washing
with 20 ml of water. Finally washed with successive 20 ml quantities of
water until the aqueous layer was no longer alkaline to phenolphthalein
solution. Transfered the ether extract to a weighed flask rinsing the
separating funnel with peroxide free ether, distiled the ether and added 3
ml of acetone to the flask. With the aid of a gentle current of a air
removed the solvent completely from the flask which was almost
immersed in boiling water and hold obliquely and rotated. Dried to
constant weight at a temperature not exceeding 80° C and dissolved the
content of the flask in 10 ml of freshly boiled ethanol (96 %) previously
neutralized to phenolphthalein solution. Titrated with 0.1 M ethanol
sodium hydroxide using phenolphthalein solution as indicator. Calculated
the Unsaponifiable matter as a percentage of the substance.
Free Fatty Acid
Boiled 250 ml of ethanol (96 %) to remove carbon dioxide, added 0.5 ml
of phenolphthalein solution, allowed to cool to 70°C and neutralized with
10g Sodium hydroxide to 100 ml of the neutral ethanol, added 10 g of the
RBW and dissolved it quickly by heating under a reflux condenser.
Cooled to 70°C and titrated at 70°C with 0.1 M sodium hydroxide (Not
more than 0.2 ml is required. If the solution is still pink added in a thin
stream 5 ml of hot barium chloride solution previously neutralized to
phenolphthalein solution, mix thoroughly and titrate with 0.1 M
hydrochloric acid until the pink color disappears not more than 1.0 ml is
required).

Iodine Value
Taken 1.0 g substance into a 250 ml flask fitted with a ground glass
stopper and previously dried or rinsed with glacial acetic acid, and
dissolved it in 15 ml of chloroform. Added very slowly 25.0 ml of iodine
bromide solution. Closed the flask and kept it in the dark for 30 min.
shaking frequently. Added 10 ml of a 100 g/l solution of potassium
iodide and 100 ml of water. Titrated with 0.1 M sodium thiosulphate
shaking vigorously until the yellow color was almost discharged. Added
5 ml of starch solution and continued the titration by adding the 0.1 M
sodium thiosulphate drop wise until the color was discharged (n1 ml of
0.1 M sodium thiosulphate). Carried out a blank test under the same
condition (n2 ml of 0.1 M sodium thiosulphate).
Refining of rice bran wax
Rice bran wax is important byproduct in the processing of rice oil, rice
bran wax main component is the ester that high fatty alcohol and higher
fatty acid form, fusing point is higher, under normal temperature with
Precipitation, rice bran wax is to extract and obtain from the byproduct
rice bran wax of refining of crude rice bran oil is stuck with paste, the
rice bran wax extracting has due value aspect a lot, as very extensive in
what apply at aspects such as food, daily use chemicals, chemical
industry.
The purifying process of rice bran wax be mainly divided into come
unstuck, de-oiling, three steps of decoloring, the most important with
de-oiling and decolorization.Wherein the method for de-oiling mainly
comprises press filtration saponification method and solvent extraction,
and wherein press filtration saponification method is to belong to
unsaponifiable according to rice bran wax, and the oil in wax is
saponified into soap lye and separation, the method technique is simple,
cost is low, but the rice bran wax obtaining is of poor quality, and
produces a large amount of waste water; And solvent extraction is to
utilize wax the dissolubility difference in organic solvent carries out
separately with oil, has quality of finished product good, yield is high, oil
content recoverable, the advantages such as non-wastewater discharge.

Decolorization of rice bran wax

For the decoloring method of rice bran wax, adopt at present strong
oxidizer oxidation style more, the method needs massive laundering to
remove metal ion, produces a large amount of waste water, and the
while is generation metal ion pollution easily, and if wash halfway
words, product purity is not high; In prior art, also utilize physical
absorbent plant ash to decolor, but no matter utilize strong oxidizer
decoloring or plant ash decoloring, its effect is unsatisfactory, and after
decoloring, the color and luster of rice bran wax also can only reach
whiteness 25 left and right preferably, has restricted the range of
application of product.
Summary of the invention
The object of the invention is to overcome the deficiencies in the prior
art, a kind of decoloring method of rice bran wax is provided, so that a
kind of rice bran wax decolouring technology of improvement to be
provided, when further improving the decolorizing effect of rice bran
wax, reduce costs.
The present invention is achieved by the following technical solutions:
A kind of decoloring method of rice bran wax, step comprises: rice bran
wax is stuck with paste and first carried out processed, add again solvent
industry hexane to carry out de-oiling processing, then under the
existence of solvent industry hexane, add the adsorption decolorizer
processing of decoloring, finally by solid-liquid separation, obtain
filtrate, described filtrate, through evaporative removal solvent industry
hexane, obtains the rice bran wax of decoloring; In the present
invention, select organic solvent industrial hexane as specific de-oiling
agent, before rice bran wax decoloring, first remove the grease in wax,
de-oiling is effective, follow-up decolorization is had to coordinative
role, in decolorization, under the existence of solvent industry hexane,
utilize adsorption decolorizer to carry out physical adsorption, under
certain temperature and mixing speed, through fully mixing, complete
pigment absorption, finally by crossing solid-liquid separation and
evaporation step, remove adsorption decolorizer and industrial hexane,
obtain the rice bran wax of decoloring; Wherein, the adsorption
decolorizer solid after solid-liquid separation can heat precipitation, and
the industrial hexane being evaporated can continue to use after
reclaiming.
The mixing discoloring agent that the activated carbon that the
attapulgite that described adsorption decolorizer preferred mass mark is
80% and mass fraction are 20% forms, attapulgite and activated carbon
have good absorptivity to pigment, but both independent results of use
are unsatisfactory, attapulgite is mixed to use with activated carbon
with 4:1 mass ratio, under the existence of industrial hexane, can
effectively remove the pigment in rice bran wax.
The preferred steps of described processed is: rice bran wax is stuck
with paste and is heated to 110 ℃, dewater 1 hour, the wax that obtains
dehydration is stuck with paste;
The preferred steps that described de-oiling is processed is: the wax of
dehydration is stuck with paste and is cooled to 60 ℃, the industrial
hexane that adds 5 times of weight, stirring and evenly mixing at 60 ℃,
obtain rice bran wax solution, again rice bran wax solution is cooled to 0
℃, stirred crystallization, obtains crystal solution, finally, by crystal
solution centrifugation, the throw out that centrifugation obtains is the
wax of de-oiling and sticks with paste; The supernatant liquor of
centrifugation is the mixing oil that contains industrial hexane, mixing oil
is squeezed into climbing-film evaporator, or evaporate in the
evaporation equipment of other prior art, industrial hexane in mixing oil
can be evaporated and separate, through condensation, reclaim, can be
recycled, it is for sale that remaining mixing oil can be used as crude oil;
In the step that this de-oiling is processed, solvent is selected and
temperature control is crucial, the wax of dehydration is stuck with
paste to temperature and be controlled at 60 ℃, add industrial hexane,
the wax paste that has guaranteed dehydration can fully be dissolved in
industrial hexane solvent, after fully dissolving, then be cooled to 0 ℃
and carry out crystallization, thereby guarantee yield and the purity of
rice bran wax;
The preferred steps that described decoloring is processed is during the
wax of de-oiling is stuck with paste, to add the industrial hexane of 5
times of weight, acquisition mixed solution, mixed solution is heated to
60 ℃, the adsorption decolorizer that adds again mixed solution 5%
weight ratio, stirs under 60rpm and decolors for 40 minutes, obtains the
mixed solution of decoloring;
Finally, the mixed solution of decoloring is carried out to solid-liquid
separation, the method of solid-liquid separation comprises squeezing in
airtight filter filters, but be not limited to the method, other any method
that can realize solid-liquid separation all should be included in
protection scope of the present invention, filtering the solid matter
obtaining is useless discoloring agent, can heat on the spot, reclaim
remaining industrial hexane solvent in useless discoloring agent, filter
the filtrate of acquisition through evaporative removal solvent industry
hexane, the method of evaporative removal solvent industry hexane
comprises to be squeezed into filtrate in vaporizer, to carry out
precipitation, now industrial hexane solvent can gasify, through
condensing tube condensation, reclaim, recycling, with cost-saving, also
can not utilize the direct evaporative removal industrial hexane of
vaporizer.
In the step that described de-oiling is processed, while starting to mix,
stirring velocity should be controlled at 60rpm hurry up conventionally,
starts cooling after 50 minutes, and while being down to 0 ℃, stirring
velocity should be down to 10rpm, and the time of stirred crystallization
is 2 hours; In crystallization process, stirring velocity is too fast, can
destroy crystal and be shaped, and stirring velocity is excessively slow,
can make crystal grain excessive, unreal, unfavorable solid-liquid
separation.
The present invention has the following advantages compared to
existing technology: the decoloring method that the invention provides
a kind of rice bran wax, the method selects industrial hexane as specific
solvent, first carry out de-oiling processing, selecting mass fraction is
that the adsorption decolorizer that activated carbon that 80%
attapulgite and mass fraction are 20% forms carries out adsorption
bleaching again, can obtain the white rice bran wax product of
whiteness nearly 32, industrial hexane in decolorization reclaims
through evaporative condenser, reusable edible, the crude oil producing
in decolorization can sell, with low cost; The method does not adopt
oxygen ant, there is no the residual of heavy metal, there is no the
participation of water, produces hardly waste water, has further
reduced production cost, has reduced again pollution, and meanwhile,
the product purity that the method decoloring obtains is high, and
quality is good, has expanded the range of application of product.
Embodiment
Below embodiments of the invention are elaborated, the present
embodiment is implemented take technical solution of the present
invention under prerequisite, provided detailed embodiment and
concrete operating process, but protection scope of the present
invention is not limited to following embodiment.
Embodiment 1
The decoloring method of a kind of rice bran wax of the present
embodiment, comprises the following steps:
(1) processed: rice bran wax is stuck with paste and is heated to 110 ℃,
dewater 1 hour, the wax that obtains dehydration is stuck with paste;
(2) de-oiling is processed: the wax of step (1) dehydration is stuck with
paste and is cooled to 60 ℃, the industrial hexane that adds 5 times of
weight, at 60 ℃, 60rpm stirs 50 minutes, obtain rice bran wax solution,
again rice bran wax solution is cooled to 0 ℃, under 10rpm, stirred
crystallization is 2 hours, obtain crystal solution, finally by crystal
solution centrifugation, the supernatant liquor of centrifugation is the
mixing oil that contains industrial hexane, mixing oil is squeezed into
and in climbing-film evaporator, carried out precipitation, industrial
hexane in mixing oil can be evaporated and separate, through
condensation, reclaim, can be recycled, it is for sale that remaining
mixing oil can be used as crude oil, the throw out that centrifugation
obtains is the wax of de-oiling and sticks with paste,
(3) decoloring is processed: the wax of step (2) de-oiling is stuck with
paste and squeezed in bleacher, the industrial hexane that adds 5 times
of weight of wax paste of de-oiling, obtain mixed solution, mixed
solution is heated to 60 ℃, the adsorption decolorizer that adds again
mixed solution 5% weight ratio, under 60rpm, stir and decolor for 40
minutes, obtain the mixed solution of decoloring, described adsorption
decolorizer is that massfraction is the mixing discoloring agent that
activated carbon that 80% attapulgite and mass fraction are 20% forms;
(4) separating treatment: the mixed solution of step (3) decoloring is
squeezed in airtight filter and filtered, filtering the solid matter obtaining
is useless discoloring agent, can heat on the spot, reclaim remaining
industrial hexane solvent in useless discoloring agent, the filtrate that
filtration obtains is squeezed in climbing-film evaporator and is carried
out precipitation, removes the industrial hexane in filtrate, obtain
decoloring wax, decoloring wax is cooled to 90 ℃, put into shaped
container molding, obtain the white rice bran wax product of whiteness
nearly.

Importance of edible wax coating on fruits and

vegetables

Fruits and vegetables are a good source of vitamins and minerals,

including folate, vitamin C and potassium. They are the excellent
sources of dietary fiber, which can help to maintain a healthy gut and
prevent constipation and other digestion problems. A diet high in fiber
can also reduce your risk of bowel cancer. Fruits and vegetables can
be classified as climacteric or non-climacteric. Climacteric fruit
continue to ripen after harvest, whereas non-climacteric do not
continue to ripen after harvest. Many important tropical fruits are
climacteric, such as banana, mango, papaya, avocado, and guava. These
fruit ripen rapidly during transit and storage, thus often requiring
rapid shipment by air. There is an opportunity with climacteric fruit,
however, to slow down ripening after harvest and thus, extend the shelf
life. This can be done with controlled atmosphere (CA) storage,
modified atmosphere packaging (MAP), or with edible coatings. In
all cases the atmosphere created is that of relatively low oxygen (O2)
and high carbon dioxide (CO2) compared to standard atmosphere. The
low O2 and high CO2 depress ethylene production which is required
to turn on ripening genes that effect color changes, aroma and
degradation of cell walls results in softening
Waxes
Waxesare esters of higher fatty acid with monohydric alcohols and
hydrocarbons and some free fatty acids. It is used to modify the
internal atmosphere and to reduce water losses of fruits and
vegetables. Waxes are used only in tiny amounts. It may turn white
on the surface of fruits or vegetables if they have been subjected to
excessive heat and/or moisture. This whitening is safe and is similar to
that of a candy bar that has been in the freezer. Commodities that may
have coatings applied include apples, avocados, bell peppers,
cantaloupes, cucumbers, eggplants, grapefruits, lemons, limes, melons,
oranges, parsnips, passion fruit, peaches, pineapples, pumpkins,
rutabagas, squash, sweet potatoes, tomatoes, turnips and yucca. The
fruit waxing method can be manual or automated. During
manufacturing, the waxy coating material is dispersed and dissolved in a
solvent such as water, alcohol, a mixture of water and alcohol.
Additives such as plasticizers, antimicrobial agents, minerals, vitamins,
colors or flavours can be added in this process. The film solutions can be
applied to fruits by several methods such as dipping, spraying, brushing
and canning followed by drying.
Importance of waxing
1. To preserve fresh fruit quality during handling and subsequent
marketing
2. To control storage atmospheric temperature
3. To extend the post harvest shelf life of fruit by reducing respiration
and delaying senescence.
Principal advantages of wax application are
1. Improved appearances of fruit
2. Reduced moisture losses and retards wilting and shriveling during
storage of fruits
3. Less spoilage specially due to chilling injury and browning
4. Creates diffusion barrier as a result of which it reduces the
availability of O2 to the tissues thereby reducing respiration rate.
5. Protects fruits from micro-biological infection
6. Considereda costeffective substitute in the reduction of spoilage when
refrigerated storage is unaffordable 7.Wax coating are used as carriers
for sprout inhibitors, growth regulators and preservatives.

METHODS OF WAX PROCESSING

Type of waxing
A. Natural waxing
On the plant when fruit attains desired stage of maturity, nature provides
them with thin coat of whitish substance, which is called bloom or
natural waxing. Natural coat is clearly visible on fruits and disappears
after harvest due to repeated handling of fruit.
Ex: apple, pear, plum, mango and grapes.
B. Artificial waxing
To Prolong the shelf life of produce some of the fruit and vegetables are
dipped in a wax emulsion and then dried for few minutes. This process
provides thin layer (<1 µ) of artificial wax on skin of the produce by
which the small pores present on the skin are fully covered and reduce
the transpiration and respiration process resulting in increased shelf life.
Artificial wax also provides good shining and luster to the produce,
which increases its.
Artificial waxes like solvent waxes, water waxes and paste or oil waxes
are used.
Methods of wax application
Performance of waxing depends on method of application. Amount of
wax applied and uniformity of application are extremely important.
Fruits should be damp dry prior to wax application to prevent dilution.
Waxes should never be diluted with water. The following methods are
commonly used

i. Spray waxing
This is most commonly used method. Fruits and vegetables which move
on the roller conveyor are sprayed with water-wax emulsion. The waxed
produce is dried in a current of air at 55°C. There are two types of spray
waxing namely low pressure spraying and high pressure atomizing.
ii. Dipping
Here fruits are dipped in water wax emulsion of required concentration
for 30 to 60 seconds. The fruits or vegetables could be waxed by keeping
them in wire boxes holding about 100 fruits (30 kg) and dipping in 30
litre capacity tank containing wax emulsion. The fruits are then removed
and allowed to dry under electric fan or in the open air or with warm air
at 54 to 55°C. The produce should be turned periodically while drying.
iii. Foam waxing
Foaming is a satisfactory means of application because it leaves a very
thin coating of wax on the fruit after the water has evaporated. A foam
generator is mounted over a suitable brush head, and water is applied to
the fruit or vegetable in the foam of foam. Spraying tends to waste wax,
but it can be recovered in catch pans.
iv. Flooding
Flooding is similar to dipping and is a safe and convenient method of
application.
Cost of wax treatment
Approximately it costs around 1 rupee for treating 100 apples/oranges,
Rs. 2.0 for 100 mangoes and about Rs. 6.0 for 40 kg. of potato.

Colouring waxes - Dyes are sometimes added to waxes for greater

consumer appeal, it is being used on red variety of Irish potatoes, sweet
potatoes, and other vegetables. They enhance the color to give the same
shade or tint as when the roots were freshly dug.
In citrus fruits, dye has been approved for general use. Citrus Red No.2 is
1-2(2,5-dimethoxy phenylazo)2-napththol with an established tolerance
of 2 ppm.

A PROCESS FOR THE PREPARATION OF

>95% PURIFIED WAX FROM WAX-SLUDGE
BRAN OIL"

A process for the preparation of >95% purified wax from wax-sludge of Bran oil by
hydraulic pressing of wax sludge in the pressure range 5-50 psi using hydraulic
press, extraction of deoited wax-sludge with non-polar solvent in a ratio of about
1:2 under stirring for a period of about 30 minute at a room temperautre ranging o
25-35 C and collection of wax layer and solvent removal from the said wax layer
under 15 inch vacuum to obtain purified wax. The rice from wax is useful as a
substitute for bees" wax and carnauba wax.

This invention relates to a process for the preparation of >95% purified wax from
wax-sludge of Bran oil. More particularly the invention relates to a process for
purification of wax from rice tons would be considered as a major edible oil for the
21st century in India. The oil has about 2-5% of wax which has a number of
industrial applications, such as for polishes, ingredient in cosmetics, and food
applications. The wax is more or less similar to bees' wax and car-nauba wax in
properties and therefore could be used as a substitute for these waxes. Rice bran
wax has a potential of 20,000 tons and could capture the export and import market
of carnauba, bees', and sugarcane waxes. The present production of wax-sludge
seems to be 10,000 tons per annum (calculated at 4% of the crude oil processed to
get the present production figure of 2.5 lakh tons of refined rice bran oil) .
The chemical composition of Japanese rice bran wax has been cited in the literature.
It contains four classes of wax lipids viz., steryl ester (C47), longer alkyl ester (C44
& C54), shorter alkyl ester(C17, C19 & C20) and hydrocarbons(C29, C31 & C33).
The main component of fatty acids were linoleic, oleic, and palmitic acid for steryl
ester; behenic, lignoceric and palmitic acid for longer alkyl ester; and oleic and
palmitic acid for shorter alkyl ester. The representative molecular species were
sitosteryl linoleate (linoleoyl sitosterol), and sitosterol oleate (oleoyl sitosterol) for
steryl ester; dotriacontanyl behenate (behenoyl
do triacontanol), octacosanyl palmitate (palmitoyl octacosanol) for longer alkyl
ester; and methyl oleate, methyl palmitate and ethyl oleate for shorter alkyl ester.
Straight-chain and alkene, and branched-chain alkene (squalene) were detected as
hydrocarbons. The principal carbon number of alkane was C29 and C31 and that of
alkene, 029, 031 and 033. Rice bran wax has been chosen as one of the waxes of the
plant source for application as a natural additive in foods, cosmetics and other
industries (polishes, carbon paper, lubricants). There are Japanese (patent
no.5311013, patent year 1978) and U.S.(patent no.69649, patent year 1979) patents
on the use of rice bran wax for coating of fruits and vegetables and as an indirect
food additive (release agent) in processing plastics packaging materials intended for
food contact applications at a maximum level of 1% of the weight of the plastics.
Rice bran wax consists almost exclusively of saturated monoesters with a typical
carbon chain length distribution of 046 to 060. This monoester distribution makes it
intermediate between the ranges of the esters found in bees's wax and carnauba
wax. However, the low level of unsaturation (low iodine value) makes rice bran
wax nearly as hard as carnauba, with almost the same melting point.
The existing processes on rice bran wax production involves use of low temperature
crystallization of wax from the oil followed by filtration using filter presses. The
filtered wax is traded as
such in India and in developed countriesf the wax-sludge is treated with a number
of solvents such as chloroform, isopropanol, acetone and methanol in succession to
prepare a wax suitable for the industry. These methods were practised only in
advanced countries during 1950-1970*s. Now pure wax is being exported by Japan
to other countries. The rice bran wax produced in Japan is prepared by the solvent
extraction methods. The solvent(s) used is a trade secret. Even supercritical
carbondioxide is being employed to prepare high quality wax. But, there is no
process for the preparation of good quality wax in India, although some rice bran oil
industries are producing a slightly hard product having entrained oil(upto 30%)
which may be called as wax of about 70% purity and not pure rice bran wax which
is twice as hard as this wax. Also to our knowledge, no process/patent is making
use of hexane at room temperature for wax purification to get a >95% purity hard
wax. In the present
invention, this soft-wax, termed as wax-sludge has been purified to get a hard wax
(by using solvent treatment) which has similar melting profile as that of carnauba
wax. Also the present invention is not expensive because about 98-100% of the
entrained oil(70% yield) is recovered and can be used for preparing edible oil apart
from obtaining 95-98% pure wax (30% yield) which fetches more value compared
to wax-sludge. The process can be performed in the industry which produces
refined rice bran oil for which the raw material wax-sludge comes from the same
industry.
The novelty in the process is that the difficult step of percolation of solvent through
wax suspension has been eliminated and a new simple method has been used, As
per the developed method based on a combination of physical and chemical
methods, wax and oil fractions are separated by using low pressure and non-polar
solvent treatment for wax-sludge with 80% entrained oil while for sludge with 70%
and below of entrained oil, only non-polar solvent treatment can be given avoiding
filtration. The wax fraction thus obtained is of >95% purity. The upgraded wax
does not contain phospholipids and has a melting point, hardness, brittleness
comparable to carnauba wax. The wax so prepared in two steps does not need
bleaching. The solvent and oil can be recovered and reused, thereby the process is
economical. The process is also quick.
The rice bran wax in pure form is not available in the country. The objective of the
invention was to remove oil from the wax-sludge (50-80% oil) and prepare a wax of
>95% purity so that this could be acceptable as an ingredient in many industries.
The commercial rice bran wax is soft, with about 50-70% oil in it and can be called
as wax-sludge. Therefore, a product of 100% purity is desired which has properties
similar to that of carnauba wax. The wax behaved similar to commercial waxes
(such as bees' wax, carnauba wax, sugar cane wax, and microcrystalline wax with
regard to melting point) marketed in India.

The wax on heating melts and sets into a compact pale brown mass on attaining
room temperature. Suspending the molten material in hexane(n-hexane, commercial
hexane of boiling range 65-70°C or food grade hexane) and cooling to room
temperature followed by removal of solvent produces a porous dull-white material
same as that of the starting material. Accordingly /'the PreConventional hydraulic
press
Accordingly the present invention provides a process for the preparation of >95%
purified wax from wax-sludge of Bran oil which comprises:
a) hydraulic pressing of wax sludge in the pressure range 5-50 psi using hydraulic
press;
b) extraction of deoiled wax-sludge with non-polar solvent of the kind such as
herein described in a ratio of about 1:2 under stirring for a period of about 30
minutes at room temperature ranging from 25-35°C;
c) collection of wax layer and solvent removal from the said wax layer under 15
inch vacuum to obtain the purified wax.
In an embodiment of the present invention, the pressure applied is in the range 5-50
psi.
In another embodiment of the present invention, the non-polar aliphatic
hydrocarbon solvent is selected from hexane, n-hexane, and any of the C5-C8
carbon chain length aliphatic hydrocarbon solvents viz., petroleum ether, pentane
hexane, heptane and octane.
In still another embodiment of the present invention, the ratio of deoiled wax-sludge
to hexane should be more than 1:2.
In another embodiment of the present invention, addition of solvent is effected at
room temperature.
In another embodiment of the present invention, purified wax is recovered by
decantation followed by solvent removal.
A process of the example is illustrated by the following example, however, it should
not limit the scope of this invention.
Example-1
9 kg of wax-sludge was pressed using a low pressure press at 30 psi to get 6.3 kg of
partially deoiled wax and 2.2 kg of the oil fraction. Later, 500g of the partially
deoiled wax was treated with 2000ml X 4 of the C6 aliphatic hydrocarbon solvent
and after
30 minutes, the wax layer and the oil layer were separated at
atmospheric pressure, desolventized under 15 inch vacuum to get
lOOg of wax of 97.5% purity and 400g of oil fraction respectively
PART -B

EQUIPMENT
DESIGN
EQUIPMENT DESIGN REPORT

CONTENT:

1. Equipment used
forthe project
2. Equipment
specification/
Equipment Details
3. Function and
application of the
Equipment used.
INTRODUCTION
Heat exchangers are devices used to transfer energy between two fluids at different
temperatures. They improve energy efficiency, because the energy already within
the system can be transferred to another part of the process, instead of just being
pumped out and wasted. In the new era of sustainability, the growing urgency to
save energy and reduce overall environmental impacts has placed greater emphasis
on the use of heat exchangers with better thermal efficiency. In this new scenario,
the plate heat exchanger can play an important role.

A plate heat exchanger is a compact type of heat exchanger that uses a series of thin
plates to transfer heat between two fluids. There are four main types of PHE:
gasketed, brazed, welded, and semi-welded. The plate-and-frame or gasketed plate
heat exchanger essentially consists of a pack of thin rectangular plates sealed around
the edges by gaskets and held together in a frame. Plate heat exchangers were first
introduced in 1923 for milk pasteurization applications, but are now used in many
applications in the chemical, petroleum, HVAC, refrigeration, dairy,
pharmaceutical, beverage, liquid food and health care sectors. This is due to the
unique advantages of PHEs, such as flexible thermal design (plates can be simply
added or removed to meet different heat duty or processing requirements), ease of
cleaning to maintain strict hygiene conditions, good temperature control (necessary
in cryogenic applications), and better heat transfer performance.
2. Mechanical characteristics

A PHE consists of a pack of thin rectangular plates with portholes, through which two
fluid streams flow, where heat transfer takes place. Other components are a frame plate
(fixed plate), a pressure plate (movable plate), upper and lower bars and screws for
compressing the pack of plates. An individual plate heat exchanger can hold up to 700
plates. When the package of plates is compressed, the holes in the corners of the plates
form continuous tunnels or manifolds through which fluids pass, traversing the plate
pack and exiting the equipment. The spaces between the thin heat exchanger plates
form narrow channels that are alternately traversed by hot and cold fluids, and provide
little resistance to heat transfer.
Thermal plates and gaskets

The most important and most expensive part of a PHE is its thermal plates, which are
made of metal, metal alloy, or even special graphite materials, depending on the
application. Stainless steel, titanium, nickel, aluminum, incoloy, hastelloy, monel, and
tantalum are some examples commonly found in industrial applications. The plates
may be flat, but in most applications have corrugations that exert a strong influence on
the thermal-hydraulic performance of the device. Some of the main types of plates are
shown in Figure 3, although the majority of modern PHEs employ chevron plate types.
The channels formed between adjacent plates impose a swirling motion to the fluids, as
can be seen in Figure 4. The chevron angle is reversed in adjacent sheets, so that when
the plates are tightened, the corrugations provide numerous points of contact that
support the equipment. The sealing of the plates is achieved by gaskets fitted at their
ends. The gaskets are typically molded elastomers, selected based on their fluid
compatibility and conditions of temperature and pressure. Multi-pass arrangements can
be implemented, depending on the arrangement of the gaskets between the plates.
Butyl or nitrile rubbers are the materials generally used in the manufacture of the
gaskets.

Figure 3.
Typical cathegories of plate corrugations.
(a) washboard, (b) zigzag, (c) chevron or herringbone, (d) protrusions and depressions
(e) washboard with secondary corrugations, e (f) oblique washboard.
Figure 4.Turbulent flow in PHE channels

Design characteristics
This section presents some of the main advantages and disadvantages of a PHE,
compared to shell-and-tube heat exchangers.

Advantages

Flexibility: Simple disassembly enables the adaptation of PHEs to new process

requirements by simply adding or removing plates, or rearranging the number of
passes. Moreover, the variety of patterns of plate corrugations available, together with
the possibility of using combinations of them in the same PHE, means that various
conformations of the unit can be tested during optimization procedures.

Good temperature control: Due to the narrow channels formed between adjacent
plates, only a small volume of fluid is contained in a PHE. The device therefore
responds rapidly to changes in process conditions, with short lag times, so that the
temperatures are readily controllable. This is important when high temperatures must
be avoided. Furthermore, the shape of the channels reduces the possibility of stagnant
zones (dead space) and areas of overheating.

Low manufacturing cost: As the plates are only pressed (or glued) together, rather than
welded, PHE production can be relatively inexpensive. Special materials may be used
to manufacture the plates in order to make them more resistant to corrosion and/or
chemical reactions.

Efficient heat transfer: The corrugations of the plates and the small hydraulic diameter
enhance the formation of turbulent flow, so that high rates of heat transfer can be
obtained for the fluids. Consequently, up to 90% of the heat can be recovered,
compared to only 50% in the case of shell-and-tube heat exchangers.

Compactness: The high thermal effectiveness of PHEs means that they have a very
small footprint. For the same area of heat transfer, PHEs can often occupy 80% less
floor space (sometimes 10 times less), compared to shell-and-tube heat exchangers .
Reduced fouling: Reduced fouling results from the combination of high turbulence and
a short fluid residence time. The scale factors for PHEs can be up to ten times lower
than for shell-and-tube heat exchangers.

Ease of inspection and cleaning: Since the PHE components can be separated, it is
possible to clean and inspect all the parts that are exposed to fluids. This feature is
essential in the food processing and pharmaceutical industries.

Easy leak detection: The gaskets have ventsthat prevent fluids from mixing in the case
of a failure, which also facilitate locating leaks.

Drawbacks
Temperature and pressure limitations: An important limitation of PHEs is related to
the plate gaskets. Pressures and temperatures exceeding 25 atm and 160 °C,
respectively, are not tolerated because they can cause the standard gaskets to leak.
However, gaskets made of special materials can withstand temperatures up to 400 °C,
and it is possible to weld or braze the plates to each other in order to operate under
more severe conditions. This would have the additional advantages of increasing the
operational limits, as well as the possibility of working with corrosive fluids, because it
would eliminate the need for gaskets. However, the PHE would lose its major
advantages of flexibility and ease of cleaning, and the equipment would become more
expensive.

High pressure drop: Because of the corrugated plates and the small flow space between
them, the pressure drop due to friction is high, which increases pumping costs. The
pressure drop can be reduced by increasing the number of passages per pass and
splitting the flow into a greater number of channels. This diminishes the flow velocity
within the channel, hence reducing the friction factor. However, the convective heat
transfer coefficient is also reduced, decreasing the effectiveness of the heat exchanger.

Phase change: In special cases, PHEs can be used in condensation or evaporation

operations,but are not recommended for gases and vapors due to the limited space
within the channels and pressure limitations.

Types of fluids: The processing of fluids that are highly viscous or contain fibrous
material is not recommended because of the high associated pressure drop and flow
distribution problems within the PHE. Compatibility between the fluid and the gasket
material should also be considered. Highly flammable or toxic fluids must be avoided
due to the possibility of leakage.

Leakage: Friction between the metal plates can cause wear and the formation of small
holes that are difficult to locate. As a precaution, it is advisable to pressurize the
process fluid so that there is less risk of contamination in the event of leakage from a
plate.

Arrangement of a plate heat exchanger

The simplest types of arrangements of plate heat exchangers are those in which both
fluids make just one pass, so there is no change in direction of the streams. These are
known as 1-1 single-pass arrangements, and there are two types: countercurrent and
concurrent. A great advantage of the single-pass arrangement is that the fluid inlets and
outlets can be installed in the fixed plate, making it easy to open the equipment for
maintenance and cleaning, without disturbing the pipework. This is the most widely
used single-pass design, known as the U-arrangement. There is also a single-pass Z-
arrangement, where there is input and output of fluids through both end plate.
Countercurrent flow, where the streams flow in opposite directions, is usually preferred
due the achievement of higher thermal efficiency, compared to concurrent flow, where
the streams flow in the same direction. Multi-pass arrangements can also be employed
to enhance the heat transfer or flow velocity of the streams, and are usually required
when there is a substantial difference between the flow rates of the streams.
Design of a plate heat exchanger

Basic equations for the design of a plate heat exchanger

The methodology employed for the design of a PHE is the same as for the design of a
tubular heat exchanger. The equations given in the present chapter are appropriate for
the chevron type plates that are used in most industrial applications.

Parameters of a chevron plate

The main dimensions of a chevron plate are shown in. The corrugation angle, β, usually
varies between extremes of 25° and 65° and is largely responsible for the pressure drop
and heat transfer in the channels.
For the effective heat transfer area, the hydraulic diameter of the channel is given by
the equivalent diameter, De, which is given by:

where bb is the channel average thickness.

Heat transfer in the plates

The heat transfer area is expressed as the global design equation:
Q=UAΔTM
where U delta is the overall heat transfer coefficient, A is the total area of heat transfer
and ΔTmis the effective mean temperature difference, which is a function of the inlet
and outlet fluid temperatures, the specific heat, and the configuration of the exchanger.
The total area of heat transfer can be given by:
A=NPAPE19

where NP is the number of plates. The end plates, which do not exchange heat, are not
taken into account in determining the area. The inner plates are usually called thermal
plates in order to distinguish them from the adiabatic end plates. The overall heat
transfer coefficient can be determined by:

where

hhot = convective heat transfer coefficient of the hot fluid

hcold = convective heat transfer coefficient of the cold fluid

tP = plate thickness

kP = plate thermal conductivity

Rf,hot = fouling factor of the hot fluid

Design methods
There are two main approaches used in the design of PHEs, namely the log-mean
temperature difference and the thermal effectiveness methods. For the first method, the
rate of heat transfer is given by:
Q=UA(F Δ Tl m) E21

where Δ Tl mis the log-mean temperature difference, given by and F is the log-mean
temperature difference correction factor.
Δ Tl m=ΔT1−ΔT2ln(ΔT1/ΔT2) E22

Where
 ΔT1={Thot,in−Tcold,out if countercurrentThot,in−Tcold,in if concurrent

ΔT2={Thot,out−Tcold,in if countercurrentThot,out−Tcold,out if concurrent if countercurrent

concurrent countercurrent if concurrent

The correction factor is a function of the heat exchanger configuration and the
dimensionless parameters R and PC. For purely countercurrent or concurrent (single-
pass) arrangements, the correction factor is equal to one, while for multi-pass
arrangements, it is always less than one. However, because the end channels of the
PHE only exchange heat with one adjacent channel, different to the inner channels that
exchange heat with two adjacent channels, purely countercurrent or concurrent flow is
only achieved in two extreme situations. These are:

1. when the PHE has only one thermal plate, so that only two channels are formed
by the end plates and the thermal plate, with each stream flowing through one
channel;
2. when the number of thermal plates is sufficiently large that the edge effect can
be neglected.

The adimensional parameters R e PCare defined as:

R=Thot,in−Thot,outTcold,out−Tcold,in=(M˙cp)cold(M˙cp)hotE23
PC=Tcold,out−Tcold,inThot,in−Tcold,in=ΔTcoldΔTmaxE24

The second method provides a definition of heat exchanger effectiveness in terms of

the ratio between the actual heat transfer and the maximum possible heat transfer, as
shown in Eq. (25):
E=QQmaxE25

The actual heat transfer can be achieved by an energy balance:

Q=(M˙cp)hot(Thot,in−Thot,out)E26

Q=(M˙cp)cold(Tcold,out−Tcold,in)E27

Thermodynamically, Qmax represents the heat transfer that would be obtained in a pure
countercurrent heat exchanger with infinite area. This can be expressed by:
Qmax=(M˙cp)minΔTmaxE28

Using Eqs. (26), (27) and (28), the PHE effectiveness can be calculated as the ratio of
temperatures:
E=⎧⎩⎨ΔThotΔTmaxΔTcoldΔTmaxif R>1if R<1<1E29
Pressure drop in a plate heat exchanger
The pressure drop is an important parameter that needs to be considered in the design
and optimization of a plate heat exchanger. In any process, it should be kept as close as
possible to the design value, with a tolerance range established according to the
available pumping power. In a PHE, the pressure drop is the sum of three
contributions:

1. Pressure drop across the channels of the corrugated plates.

2. Pressure drop due to the elevation change (due to gravity).
3. Pressure drop associated with the distribution ducts.

The pressure drop in the manifolds and ports should be kept as low as possible, because
it is a waste of energy, has no influence on the heat transfer process, and can decrease
the uniformity of the flow distribution in the channels. It is recommended to keep this
loss lower than 10% of the available pressure drop, although in some cases it can
exceed 30%.
Optimization

Any industrial process, whether at the project level or at the operational level, has
aspects that can be enhanced. In general, the optimization of an industrial process aims
to increase profits and/or minimize costs. Heat exchangers are designed for different
applications, so there can be multiple optimization criteria, such as minimum initial and
operational costs, minimum volume or area of heat transfer, and minimum weight
(important for space applications).
CONCLUSIONS
In this chapter it was presented the development of two models for the design and
optimization of plate heat exchangers. Both mathematical models were used to
accomplish the heat exchanger design simulations. These methods use differential
equations and closed-form equations based on the notion that a multi-pass PHE can
be reduced to an arrangement consisting of assemblies of single-pass PHEs.
As a case study, an example obtained from the literature was used. The optimal sets
were the same for both approaches, and agreement was achieved between the
effectiveness values. The model using algebraic equations has the limitation of only
being applicable to PHEs sufficiently large not to be affected by end channels and
channels between adjacent passes. However, industrial PHEs generally possess
more than 40 thermal plates. The major advantage of using this model is its general
applicability to any configuration, without having to derive a specific closed-form
equation for each configuration. However, its drawback is the highly complex
implementation of the simulation algorithm, unlike the second approach, which is
very simple.
 PART-C

TECHNO-ECONOMIC
FEASIBILITY REPORT
NAME OF THE UNIT:L.V.PVT .LTD

LOCATION: KOLKATA

REGISTERED OFFICE:UPSIDC, Roma Industrial Area, NH-2 Road, Kanpur

NAME OF THE PARTNER(S): ASHUTOSH SHUKLA

SHUBHAM KUMAR YADAV

4. ITEM OF MANUFACTURE: RICE BRAN WAX

INSTALLED CAPACITY:2TPD

PROPOSED CAPACITY FOR THREE

ONWARDS YEARS OF THE PRODUCTION:60%, 70%, 80%

POWER REQUIREMENTS:500unit/day

EMPLOYMENT POTENTIAL:26nos.
 \

ASSUMPTION:

1. Type of Plant -: RICE BRAN WAX Manufacturing Plant

2. Capacity: 2 TPD

3. No. of days operated: 300

4. Interest levied by financial institution: 10%

5. Depreciation: 5% on Building and 15% on Machinery

6. Rice BranWax is obtained from local market as well as from import.

7. 70% of project cost would be obtained from financial institutions. Rest would be
provided by promoters.

8. Construction and erection period is 18 months.

9. Sale of Rice bran wax would be done as packaged product sale to market and
around 1000 packets are estimated to sold on daily basis.

10. All Costs are in rupees and are estimated values.

 Cost of Project

1. Land -:

Area of land :4000 sq. M

Circle rate : 5000/sq. M
Entities Calculation Cost

Cost of land 2000×5000 1,00,00,000

Site development charges 10,00,000

(earth filling , boring etc.)

Registration + Stamp Duty (12.5 + 2)% of cost of land 14,50,000

Total 1,24,50,000

2.BUILDING:

Entities Cost

Construction 20,00,000
RCC 5,00,000
Electrification 3,00,000
Other expenses 50,000

Total 28,50,000
 2. Machinery and Equipments -:
Entities Cost

2 TPD Hydraullic Press cost{2} 20,00,000

Boiler, ETP, Chiller, cooling tower 1,00,00,000

500 kg De oiling section (solvent 20,00,000

extraction.){2}
Total 1,40,00,000

3. Miscellaneous Fixed Assets = 1,00,000

4. Escalation and Contingencies = 10%of (total cost of Building,

Machinery &Equipments and Miscellaneous Fixed Assets)
= 10% of (28,50,000 + 1,40,00,000 + 1,00,000)
= 10% of (1,69,50,000)
= 16,95,000

5. Preliminary and preoperative expense = 1,00,000

6. Interest during Construction Period = 1,00,000

7. Margin Money for Working Capital -:

Entities Calculation Cost

Raw Material 15 x 4,00,000 60,00,000

Goods in Process 1,00,000
Stock and Deters 15 x 2 x 40,000 12,00,000
Miscellaneous 15 x 16,566 2,48,500
(Wages)
Total 25% of all the above 18,87,125
entities

8. Total Cost of Project -: 3,31,82,125

 Viability Report

1. Salaries (per month)-:

Job Description (No. of Employee) Net Salary

Unit head (1) 50,000

Process manager (1) 40,000
Lab Head (1) 40,000
Process Engineers (2) 50,000
Boiler incharges (1) 20,000
Packaging in-charge (1) 25,000
Operators (4) 60,000
Accounts + HR + maintenance + dispatch (3) 1,00,000
Security personnel (4) 40,000
Lab chemists (2) 30,000
Casual workers (6) 42,000
Total 4,97,000
Per day salary 16,566

2. Raw material (per day) -:

Name Amount Cost Net

Hexane 6,000 kg 40/kg 3,60,000

Crude wax 2,000 kg 20/kg 40,000

 Total 4,00,000

3. Packaging Material Requirement(per day) -:

Cost (@ Rs. 1/kg of Wax packed) = 2×1000 = 2000

4. Utilities(per day) -:

Name Amount Cost Net

Steam 2000 kg 2/kg 4,000

Electricity 500 units 14/unit 70,000

Fuel (husk) 500 kg 2/kg 1,000

Other 6,000
Total 81,000

5. Other contingent expenses (per day) -:

Entities Net Amount

Maintenance and repair 1,000

Transportation 5,000

Selling + publicity 2,000

Telephone + Wi-Fi 200

Insurance 500

Stationary , furniture, store 1000

Total 9700
6. Depreciation (yearly) -:

Entities Calculation Amount

Building 5% of cost of 1,02,500
Building
Machine 15% of cost of 21,00,000
Machinery and
Equipments
Total 22,02,500

7. Miscellaneous expenses (yearly) = (0.5% of daily expenses)

= 17,702.5

8. Interest on term loan (yearly) = (10% of 70% of Total cost of project)

= 23,22,748

9. Interest on working capital (Yearly) = (10% of 75 % of MMWC)

= 1,41,534

10. Total cost of production = (Sum of all the above entities in viability report)
(yearly) = 15,81,58,484.5

11. Sales Realization(annual) -:

i. Wax for selling = 1200kg/day X 300 days = 360,000 kg

 Selling price in market = 500/kg
Sale accruals = 360,000 X500 = 18,00,00,000
ii. Recovery (annual) -:

Entities Amount Cost per Net

unit

Recoverd Oil 776kg/day x 300 days 80/kg 1,86,24,000

Total 1,86,24,000

Total Sales Realization = 19,86,24,000

12. Gross Profit=19,86,24,000 – 15,81,58,484 = 4,04,65,516

13. Income Tax on Gross Profit -: 30% x 4,04,65,516 = 1,21,39,654

14. Net Profit = 4,04,65,516 – 1,21,39,654 = 2,83,25,862

15. Total Depreciation = 22,02,500

16. Cash accruals = 22,02,500+ 2,83,25,862= 3,05,28,362

 Payback Period

Original Investment = -3,31,82,125

Year Cash Inflow Cumulative Cash inflow

0 -3,31,82,125 -3,31,82,125
1 3,05,28,362 -2653763
2 33581198 30927435

In the second year,

Total Amount required to recover in 2nd year = 30927435

Therefore,recover in 2.079 YEAR

Hence, it would take2.079 YEAR to recover our original investment i.e. Payback
Period is2.079 YEAR

Break Even Point

Break-even point = [(FC/ (Sales - VC)) x 100] %

Fixed Cost = 16566 + 6363 + 59 + 9700= 32,688

Sales = 198624000 / 300 = 662080

Variable Cost = 400000+ 2000 + 81000 + 387 = 4,83,387

Break Even Point = [(32,688/ (662080- 483387)) x 100] %

= [(32688 / 178693) x 100] %
= 18.29%
 References

 Van Nieuwenhuyzen, W., 1976. Purified wax andproperties. Journal of the

American Oil Chemists' Society, 53(6Part2), pp.425-427.

 Szuhaj, B. F. "rice bran wax production and utilization." Journal of the

American Oil Chemists' Society 60, no. 2Part1 (1983): 306-309.

 Sangkram, Uma, and AthapolNoomhorm. "The effect of drying and storage of

rice bran wax on the quality of it, ." purification Technology 20.10 (2002):
2041-2054.

 Wendel, A. (2000). Lecithin. Kirk‐OthmerEncyclopedia of chemical

technology.

 Google-images for various figures used in the project.

 van Nieuwenhuyzen, W., 2010. Rice bran wax and other WAXs. Waxs from
renewable resources, pp.191-212.

 List, G.R., 2015. Bran wax : Food, industrial uses, and other
applications. Polar Lipids, pp.1-33.

 FATTY ALCOHAL . "Final report on the safety assessment of bran wax

andpurified bran wax " Int. J. Toxicol 20.1 (2001): 21-45.

 Erickson, David R. “ purification and utilization." Practical handbook of

purification and utilization. AOCS press, 1995. 174-183.

 MA, S. P., YANG, Z. R., TU, W. P., & CHEN, H. Q. (2002). Review of plate
heat exchanger mechanism design principal of various heat equipment.
[J]. Chemical Industry and Engineering, 2.