“Production of Refined Rice bran Wax”

BACHELOR OF TECHNOLOGY
IN
OIL TECHNOLOGY

HARCOURT BUTLER TECHNICAL

UNIVERSITY
Name - Prashant Singh
Sachin Kumar
Class - Final Year
Branch - Oil Technology
Roll no - 200111006, 200111011
 RICE BRAN WAX ?

 Rice Bran Wax is a high melting point vegetable wax obtained

from winterization of rice bran oil.

 Rice Bran Wax primarily consists of high molecular weight

monoesters ranging from C-46 to C-66.

 Our refinement process allows the wax to retain policosanols,

phospholipids, phytosterols and squalene for superior quality.

 It is ester of saturated fatty acid and long chain alcohol.

Grading of rice bran wax
Physio-chemical properties of rice bran wax
 Purification of rice bran wax

HYRAULLIC PRESS SOLVENT EXTRACTION

HYDRAULLIC PRESS METHOD

 Hydraulic pressing of wax sludge in the pressure

range 5-50 psi using hydraulic press.

 Rice bran wax sludge consists of 28- 32 % of oil

in it.
 We use PP bags of 22 kg of quantity to separate
out the oil from the wax sludge with help of
hydraullic press.

Final oil left behind is 8-10% in the pressed wax .

SOLVENT EXTRACTION METHOD

 Extraction of de-oiled 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

 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..

 Purified wax is recovered by decantation followed by solvent removal.

 The purified wax we getting about 97.5% pure.

LAB ANALYSIS .

 9 kg of wax-sludge was pressed using a low pressure press at 30 psi to get 6.3 kg of partially
de-oiled wax and 2.2 kg of the oil fraction. Later, 500g of the partially de-oiled 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

Atomospheric pressure, desolventized under 15 inch vacuum to get

lOO g of wax of 97.5% purity and 400g of oil fraction respectively

EQUIPMENT DESIGN
Plate heat exchangers
 The heat transfer surface consists of a number of thin corrugated plates pressed out of a high
grade metal
 .
 The pressed pattern on each plate surface induces turbulence and minimises stagnant areas and
fouling.

 Unlike shell and tube heat exchangers, which can be custom-built to meet almost any capacity
and operating conditions, the plates for plate and frame heat exchangers are mass-produced
using expensive dies and presses.

 All plate and frame heat exchangers are made with what may appear to be a limited range of
plate designs.
Hot and Clod Flows through Plate Heat Exchangers
Hot and Clod Flows through Plate Heat Exchangers
 Performance of Plate Heat Exchanger
 Superior thermal performance is the hallmark of plate heat exchangers.

 Compared to shell-and-tube units, plate heat exchangers offer overall heat transfer
coefficients 3 to 4 times higher
.
 These values, typically 4000 to 7000 W/m2 °C (clean), result in very compact
equipment.
S

 This high performance also allows the specification of very small approach temperature
(as low as 2 to 3°C) which is sometimes useful in geothermal applications.

 This high thermal performance does come at the expense of a somewhat higher pressure
drop.
 Selection of a plate heat exchanger is a trade-off between U-value (which influences
surface area and hence, capital cost) and pressure drop (which influences pump head
and hence, operating cost).
 Increasing U-value comes at the expense of increasing pressure drop.
Classification of Plate Heat Exchanger

 Gasketed plate heat exchangers (plate and frame heat

exchangers)
 Brazed plate heat exchangers
 Welded plate heat exchangers
Gasketed plate heat exchangers
 The Characteristic Parameter
 Thermal length is a dimensionless number that allows the design engineer to
relate the performance characteristics of a channel geometry to those of a duty
requirement.
 Thermal length (Θ) is the relationship between temperature difference DT on one
fluid side and LMTD.
 The thermal length of a channel describes the ability of the channel to affect a
temperature change based on the log mean temperature difference (LMTD).
Tin  Tout

LMTD

 The thermal length of a channel is a function of the channel hydraulic diameter, plate length, and the angle of the corrugations, along with the

physical properties of the process fluids and available pressure drop.

 To properly design a PHE, the thermal length required by the duty must be matched with that achievable by the selected channel geometry.
  Central Idea

A Plate HX is said to be Optimally Sized, if the

thermal length required by the duty can match the
characteristic of the channel, by utilizing all the
available pressure drop with no over-dimensioning,
for any chosen channel geometry.
Controlled Designs

 Thermally Controlled Designs:

 If the design exceeds the allowable pressure drop for a given thermal duty.
 More plates be added and pressure drop is reduced by lowering the
velocity.
 Such a design is termed thermally controlled.
 Hydraulically Controlled Designs:
 If the design pressure drop is than the allowable pressure drop.
 This results in a greater temperature change across the plate than required,
or over-dimensioning.
 Few plates be removed and pressure drop is increased by increasing the
velocity.
 Such a design is termed pressure drop controlled.
An Economic Design
 To have the most economical and efficient exchanger it is
critical to choose, for each fluid, a channel geometry that
matches the thermal length requirement of each fluid.
 Since thermal length achievable by a channel depends on
the physical properties of the fluid, correction factors must
be considered when the fluid’s physical properties differ
from those for standard fluid (water
STANDARD PLATE HEAT EXCHANGERS

 Today’s conventional heat transfer plate designs are

classified as chevron or herringbone type, with the
corrugations forming a series of patterns.
 Each plate size is pressed with two different chevron
angles, the low theta plate and high theta plate, and have
acute and obtuse apex angles, respectively.
 Plates
Inlet / outlet Media 2 Inlet / outlet Media 1

Distribution area

Fully supported gasket groove

Heat transfer area

Distribution area
Inlet / outlet Media 2
Inlet / outlet Media 1

engineering-resource.com
 Conventional heat transfer plates and channel
combinations.
PLATE GEOMETRY
 Chevron Angle: This important
factor, usually termed b, is
shown in Figure, the usual range
of b being 25°-65°.
 Effective Plate Length : The
corrugations increase the flat or
projected plate area, the extent
depending on the corrugation
pitch and depth.
 To express the increase of the
developed length, in relation to
the projected length, an
enlargement factor f is used.
 The enlargement factor varies
between 1.1 and 1.25, with 1.17
being a typical average.
 The value of f is also expressed as the ratio of the actual effective
area as specified by the manufacturer, A1, to the projected plate
area : A1p
Lp and Lw can be estimated from the port distance Lv and Lhand port
diameter Dp as:
TECHNO ECONOMIC FEASIABLITY REPORT
NAME OF THE UNIT: P.S. PVT .LTD

LOCATION: Kanpur

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

NAME OF THE PARTNER(S): SACHIN KUMAR

PRASHANT SINGH

ITEM OF MANUFACTURE: PRODUCTION OF REFINED RICE BRAN WAX

INSTALLED CAPACITY: 2TPD
PROPOSED CAPACITY FOR THREEONWARDS YEARS OF THE PRODUCTION:
60%, 70%, 80%
POWER REQUIREMENTS: 500unit/day
EMPLOYMENT POTENTIAL: 26nos.
COST OF PROJECT

Entities Calculation Cost

Cost of land 2000×5000 1,00,00,000

1. LAND
Site development charges 10,00,000
Area of land : 2000 sq. M (earth filling , boring etc.)
Circle rate : 5000/sq. M
Registration + Stamp Duty (12.5 + 2)% of cost of land 14,50,000

Total 1,24,50,000
 Entities Cost
 2.BUILDING:
Construction 20,00,000

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

Total 28,50,000

3. Machinery and Equipments -:

Entities Cost

2 TPD Hydraullic Press 20,00,000

cost{2}

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

tower

500 kg De oiling section 20,00,000

(solvent extraction.){2}

Total 1,40,00,000
4. Miscellaneous Fixed Assets = 1,00,000

5.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

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

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

8. Margin Money for Working Capital -:

Entities Calculation Cost

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

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

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

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
 Name Amount Cost Net
2.Raw material (per day) -:

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

Name Amount Cost Net

4. Utilities (per day) -:
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
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) -:

A-Wax for selling = 1200kg/day X 300 days = 360,000 kg

Selling price in market = 500/kg
Sale accruals = 360,000 X 500 = 18,00,00,000
 B. 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 take 2.079 YEAR to recover our original investment i.e. Payback
Period is 2.079 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%