Detailed Project Report (DPR) on CASTOR OIL AND ITS DERIVATIVES (OLEORESIN, TURKEY RED OIL, DCO, HCO, SEBACIC ACID, 12-HYDROXY STEARIC ACID WITH COLD PRESSED, CP GRADE, COMMERCIAL GRADE, SPECIAL FIRST GRADE CASTOR OIL)

CASTOR OIL AND ITS DERIVATIVES
(OLEORESIN, TURKEY RED OIL, DCO, HCO, SEBACIC ACID,
12-HYDROXY STEARIC ACID WITH COLD PRESSED, CP GRADE, COMMERCIAL GRADE, SPECIAL FIRST GRADE CASTOR OIL)

 [CODE NO. 3014]

Castor oil is derived from the seeds of the plant Ricinus Communis, which occurs naturally in almost all tropical and near-tropical areas as a perennial. It is also Widely found in temperate climates, but where frost occurs, the plant must be cultivated as an annual.

The seeds of the plant, commonly called castor beans, grow in clusters on spikes of the plant. The seed or bean itself is encased in a spiny outer shell, from which it may be separated by mechanically dehulling, or by sun-drying in the open until the casing splits. The bean itself consists approximately of 75% kernel and 25% husk. The oil content of the whole seed varies between 35-55%. A typical analysis will show: moisture - 5. 5%; oil -48.6%, protein - 17.9%; carbohydrate - 13.0%; fiber - 12.5%; and ash - 2.5%.

The oil is a rarity in nature, being almost a pure compound - about nine-tenths the glyceride of ricinoleic acid. The average fatty acid composition of castor oil is 86% ricinoleic, 8% oleic, 3%- linoleic. and 3% stearic and dihydroxystearic.

Although the mealy residue of bean following oil extraction is high in protein (about 35%) it is not suitable for use as a foodstuff due to the presence of the toxic albumin ricin. The ricin may be deactivated to some degree by steaming or heating. but since the bean also contains heat-stable allergenic materials, it is advisable not to use it as a feed ingredient.

The major usage for extracted castor-bean meal is as a fertilizer for which use it is eminently suited. It releases its nitrogen content slowly. and is quite high in humus value. Further, the meal also contains several other elements of plant food.

Two grades of castor oil are recognized in the United States. These are No. 1 oil, consisting of the first pressing (cold) of the oil seeds. This pressing is followed by bleaching and filtration with activated carbon or earths. The No.. 1 oil is light in color, brilliant. and low in acidity. It is suitable for use in medicinal preparations.

The other grade of oil is No.3. This is extracted from the press cake from No. I oil pressing by means of hydrocarbon solvents. The No. 3 oil is darker in color, and higher in acidity than cold pressed oil, and is considered unsuitable for medicinal purposes.

Castor Oil Derivatives

For uses other than medicinal or lubrication, castor oil may be processed in several ways:

1) Sulfonation: Treatment of castor oil with concentrated sulfuric acid yields the sulfonated (actually sulfated) ester known as "Turkey-red" oil. This product is an anionic wetting agent widely used in textile drying and finishing.

2) Blown or Oxidized Castor Oils: Bringing castor oil into intimate contact with air or oxygen at elevated temperatures produces an oxidized or partially polymerized oil in a wide range of viscosities, color3, and acid values. These oxidized oils are used as plasticizers or elasticizers in the manufacture of nitrocellulose films, artificial leathers and oilcloths.

3) Dehydration: The dehydration of castor oil can be controlled to yield two d1stinct types of material. One is the partially dehydrated oil which is soluble in mineral oil or glycols. Although this oil was once widely used as a lubricant it has been supplanted in recent years by specially "tailored" mineral lubricants. Its major present use is due to its low viscosity index -- in shock absorber fluids and brake and hydraulic fluids.

Fully dehydrated castor oil is an excellent drying oil, the equivalent of good tung oil. This dehydrated 0il is the largest single present use of castor oil. The oil is dehydrated by heating to elevated temperatures, in vacua, in the presence of metallic salt catalysts.

4) Hydrogenation: The complete hydrogenation of castor oil yields essentially trihydroxystearin. m. p. 85-870C. a waxy fat. Partial hydrogenations will yield intermediate melting point fats. Hardened castor oils are utilized in the manufacture of certain waxes, ointments and cosmetics. Hydrogenation is accomplished under H2 pressure and moderately elevated temperatures in the presence of nickel catalyst.

5) Saponification: Saponified castor oil is used to a minor degree in the production of lathering soaps. More recently, it has been used in increasing amounts as a chemical intermediate and as a source of such dibasic organic acids as suberic, sebacic, and azelaic, used for manufacture of nylon-type polymers.


COST ESTIMATION

Plant Capacity                                                21960.00 Kgs/day
Land & Building (4000 Sq.Mtr)                    Rs. 2.99  Cr
Plant & Machinery                                          Rs. 2.00  Cr
W.C. for 2 Months                                          Rs. 12.71  Cr
Total Capital Investment                              Rs. 17.87  Cr
Rate of Return                                               45%
Break Even Point                                           32%


INTRODUCTION    
PROPERTIES AND SPECIFICATION OF CASTOR OIL GRADES AND DERIVATIVES    
HYDROGENATED CASTOR OIL    
DEHYDRATED CASTOR OIL    
PROPERTIES AND COMPOSITION    
USES AND APPLICATION    
HYDROGENATED CASTOR OIL (HCO)    
DEHYDRATED CASTOR OIL    
FIRST SPECIAL GRADE (FSG) CASTOR OIL    
MARKET SURVEY           
CURRENT END USES FOR CASTOR OIL & DERIVATIVES    
DEMAND OF HYDROGENATED CASTOR   
DEMAND OF DEHYDRATED CASTOR OIL    
COLD PRESSED CASTOR OIL    
BENEFITS OF COLD PRESSED CASTOR OIL    
DERIVATION AND SPECIFICATIONS OF DIFFERENT GRADES
  (CASTOR OIL AND DERIVATIVES)    
MANUFACTURING PROCESS OF CASTOR OIL    
DETAILED MANUFACTURING PROCESS OF CASTOR OIL    
EXPRESSION PLANT FLOW SHEET    
EXPRESSION EXTRACTION PLANT FLOW SHEET    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF COMMERCIAL GRADE CASTOR OIL    
PROCESS FLOW DIAGRAM OF COMMERCIAL CASTOR OIL    
MANUFACTURING PROCESS OF CASTOR OIL (FIRST SPECIAL GRADE)    
PROCESS FLOW DIAGRAM OF FIRST SPECIAL GRADE CASTOR OIL    
MANUFACTURING PROCESS OF CASTOR OIL (COLD PRESSED GRADE)    
PROCESS FLOW DIAGRAM OF COLD PRESSED CASTOR OIL    
MANUFACTURING PROCESS OF PP GRADE CASTOR OIL    
MANUFACTURING PROCESS OF B.P. GRADE CASTOR OIL    
MANUFACTURING PROCESS OF DCO (DEHYDRATED CASTOR OIL)    
MANUFACTURING PROCESS FOR CASTOR OIL DERIVATIVE OLEORESIN    
PERFORMANCE MEASURMENTS IN FRACTIONAL DISTILLATION COLUMN    
PROCESS FLOW DIAGRAM FOR CASTOR OIL DERIVATIVE OLEO-RESIN    
MANUFACTURING PROCESS OF SULPHONATED CASTOR OIL (TRO)    
PROCESS FLOW SHEET FOR TURKEY RED OIL    
MANUFACTURING PROCESS IN DETAILS FOR DEHYDRATED CASTOR OIL (DCO)    
PROCESS FLOW SHEET OF DEHYDRATED CASTOR OIL (DCO)    
MANUFACTURING PROCESS OF HCO (HYDROGENATED CASTOR OIL) IN DETAILS    
PROCESS FLOW SHEET FOR HCO    
HYDROGENATED CASTOR OIL (HCO) FLAKES/POWDER    
MANUFACTURING PROCESS OF SEBACIC ACID    
METHOD FOR PREPARING SEBACIC ACID AND OCTANOL-2    
MANUFACTURING PROCESS OF 12-HYDROXY STEARIC ACID    
RAW MATERIAL CALCULATION FOR OLEORESIN    
MATERIAL SAFETY DATA SHEET (MSDS) FOR REFINED CASTOR OIL
  FIRST SPECIAL GRADE (FSG)    
TEST PARAMETERS OF FIRST SPECIAL GRADE CASTOR OIL    
SUPPLIERS OF PLANT AND MACHINERY     
SUPPLIERS OF RAW MATERIALS    

APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET