Detailed Project Report (DPR) on converting crude glycerine to refined glycerine

CONVERTING CRUDE GLYCERINE TO REFINED GLYCERINE
[CODE NO.3606]  

Glycerol, also known as glycerine or propane-1,2,3-triol, is a chemical which has a multitude of uses in pharmaceutical, cosmetic, and food industries. It can be produced as a by-product from saponification and hydrolysis reactions in oleochemical plants as well as transesterification reaction in biodiesel plants. Glycerol produced from oleo chemical or biodiesel plant is in crude form that contains various impurities such as oily, alkali, and soap components, a salt or diols, depending on the processes and the type of materials processed. It is normally referred to as crude glycerol. Crude glycerol obtained from the biodiesel plant consists of glycerol, water, organic and inorganic salts, soap, alcohol, traces of glycerides and vegetable colour. While crude glycerol produced from the hydrolysis reaction contains glycerol, water, free fatty acid, unreacted triglycerides, organic and inorganic salts and matter organic non-glycerol. For the reaction of saponification of fats or oil, crude glycerol has been reported to contain glycerol, fatty acids and salts. Further crude glycerol is a low value product as its low purity limits its application as feedstock in industries. The development of conversion processes for crude glycerol to other value-added products is being thoroughly investigated; however, the techniques are not widely commercially adopted in Malaysia at present. Purified glycerol can be sold as a commodity because it is still highly required as an important industrial feedstock especially in various chemical industries. Consequently, a development of purification methods is necessary to produce highly purified glycerol as feasible industrial feedstock.

Presently, numerous purification techniques of crude glycerol have been developed such as conventional filtration, microfiltration, and ultrafiltration using organic polymer membranes, simple distillation, vacuum distillation, chemical and physical treatments, ion-exchange technique and adsorption. By combining two or more of these techniques would lead to higher purify glycerol. This paper reviews the methods employed to produce glycerol as well as the purification technologies.


COST ESTIMATION

Plant  Capacity                                                :    10.00 MT/day    
land & Building (4000 Sq.Mtr)                      :    Rs. 2.24  Cr
Plant & Machinery                                           :    Rs. 1.10  Cr
Working Capital for 2 Months                       :    Rs. 2.43  Cr
Total Capital Investment                                :    Rs. 5.97  Cr
Rate of Return                                                 :    36%
Break Even Point                                            :    45%


INTRODUCTION    
SYNTHETIC GLYCEROL    
PROPERTIES OF GLYCERINE    
PHYSICAL PROPERTIES -    
CHEMICAL PROPERTIES    
3.SPECIFIC GRAVITY AT 25/25OC OF VARIOUS CONCENTRATION OF GLYCEROL.    
SOURCE OF GLYCEROL    
TRANSESTERIFICATION REACTION    
ACID CATALYSED TRANSESTERIFICATION    
BASE CATALYSED TRANSESTERIFICATION    
TABLE: ADVANTAGES & DISADVANTAGES OF VARIOUS TYPES OF CATALYST
USED IN TRANSESTERIFICATION REACTION. (MODIFIED FROM REF.).    
ENZYMATIC CATALYSED TRANSESTERIFICATION    
SAPONIFICATION    
HYDROLYSIS    
USES AND APPLICATIONS    
FOOD INDUSTRY    
PHARMACEUTICAL AND PERSONAL CARE APPLICATIONS    
BOTANICAL EXTRACTS    
ELECTRONIC CIGARETTE LIQUID    
ANTIFREEZE    
INTERNAL COMBUSTION FUEL    
CHEMICAL INTERMEDIATE    
APPLICATION OF GLYCERINE (% AGE)    
B.I.S. SPECIFICATION    
TEST AND ANALYSIS OF GLYCERINE    
INTERNATIONAL STANDARD METHODS. ANALYSIS OF CRUDE GLYCERINE    
SAMPLING    
ANALYSIS    
WEIGH THE ASH.    
ACETIN PROCESS FOR GLYCEROL DETERMINATION    
REAGENTS REQUIRED    
THE METHOD    
BICHROMATE PROCESS    
FOR GLYCEROL DETERMINATION    
REAGENTS REQUIRED    
THE METHOD    
NOTES;    
INSTRUCTIONS FOR CALCULATING ACTUAL GLYCEROL CONTENT    
IMPURITIES IN CRUDE GLYCERINE    
OVERVIEW OF GLYCERINE MARKET    
INCREASING PRODUCTION AND DEMAND FOR BIODIESEL    
PHARMACEUTICAL APPLICATION WILL CONTINUE TO DOMINATE THE MARKET    
ASIA-PACIFIC REGION TO LEAD THE MARKET    
GLYCERINE MARKET    
CONVENTIONAL TECHNIQUES FOR PURIFYING GLYCERIN    
A NEW APPROACH    
PROCESS STEPS    
MARKET POSITION    
PRODUCTION OF GLYCERINE    
IMPORT OF GLYCERINE IN INDIA    
IMPORT DATA OF REFINED GLYCERINE    
EXPORT DATA OF REFINED GLYCERINE    
MARKET OVERVIEW (GLOBAL)    
MANUFACTURERS/SUPPLIERS OF REFINED GLYCERINE    
MANUFACTURER/SUPPLIERS OF SPENT LYE    
AND CRUDE GLYCERINE    
AN INNOVATION IN GLYCERIN PURIFICATION    
CONVENTIONAL TECHNIQUES FOR PURIFYING GLYCERIN    
A NEW APPROACH    PROCESS STEPS    
PURIFICATION OF CRUDE GLYCEROL    
SOURCE OF CRUDE GLYCERINE    
MANUFACTURING PROCESS    
OF CRUDE GLYCERINE REFINING    
DEAERATION    
DISTILLATION    
CONDENSATION    
BLEACHING    
SALT REMOVAL    
PROCESS FLOW DIAGRAM    
GLYCERINE REFINING PROCESS    
PROCESS IN DETAILS    
INTRODUCTION TO MANUFACTURING PROCESS:    
CRUDE GLYCERINE FROM VARIOUS    
PRODUCTION PROCESSES    
FIG. HYDROLYSIS REACTION.    
MANUFACTURE OF GLYCERINE FROM SPENT SOAP LYES    
PROCESS OUTLINE OF GLYCERINE MANUFACTURE    
MANUFACTURING PROCESS OF GLYCERINE FROM SPENT LYE    
RAW MATERIALS    
PROCESS FLOW DIAGRAM    
DETAILS OF GLYCEROL (GLYCERINE) MANUFACTURE FROM SPENT LYE    
SPENT LYE TREATMENT:-    
CONCENTRATION OF GLYCEROL LIQUORS    
THE EVAPORATOR AND OPERATION:-    
REFINING:    
BLEACHING OF GLYCERINE:-    
BIO DIESEL AND GLYCERINE PRODUCTION    
USING PALM OIL AS FEED STOCK    
PROCESS FLOW DIAGRAM FOR GLYCERINE USING CRUDE PALM OIL    
RECOVERY METHOD OF GLYCERINE    
OTHER METHODS OF RECOVERY:    
QUALITY OF SPENT LYES:    
THE TREATMENT AND EVAPORATION OF LYES:    
DISTILLATION OF CRUDE GLYCERINE:    
FOOTS:    
PRODUCTION OF GLYCERINE FROM PALM KERNEL OIL    
MATERIALS    
METHOD    
RESULTS AND DISCUSSION    
TABLE: PROPERTIES OF PALM KERNEL OIL USED    
TABLE: PARAMETERS OF HYDROLYSIS REACTION AND PRODUCTION
AT 268OC, PRESSURE    
500PSI (34ATM), TIME 5 HOURS.    
TABLE: DATA OF GLYCEROL RECOVERY AT TEMPERATURE 140OC,
PRESSURE 8.7PSI (0.6ATM), TIME 3 HOURS    
TABLE: PROPERTIES OF CRUDE GLYCEROL PRODUCED.    
CONCLUSIONS FROM THIS STUDY THE FOLLOWING CONCLUSION ARE MADE    
SUPPLIERS OF RAW MATERIALS    
SODIUM HYDROXIDE    
ACTIVATED CARBON    
LABORATORY CHEMICALS    
SUPPLIERS OF PLANT AND MACHINERY (GLOBAL)    
SUPPLIERS OF PLANT AND MACHINERY (INDIAN)    
TREATMENT TANK    
FILTER PRESS    
EVAPORATORS    
HEAT EXCHANGER    
CENTRIFUGE    
STORAGE VESSEL    
BOILER    
INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS    
LABORATORY EQUIPMENTS    
PACKAGING MACHINE    

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