UNIVERSITAS INDONESIA HALAMAN JUDUL CHEMICAL PLANT DESIGN Off-Grid Solar Electricity for Biodiesel Plant Report Assignment 1 GROUP 15 GROUP PERSONEL Agil Ramadhan Primasto (1206223940) Beatrix Gloria (1206263263) Harly Ilyasaakbar (1206263313) Muchtazam Mulsiansyah (1206221683) Muhammad Husein Shahab (1206223890) DEPARTMENT OF CHEMICAL ENGINEERING FACULTY OF ENGINEERING UNIVERSITAS INDONESIA DEPOK 2015 EXECUTIVE SUMMARY Biodiesel production in our plant has several main raw material according to raw material selection, which is Jatropha seeds, methanol, hydrochloric acid, and sodium hydroxide. From the consideration we made in process selection, we have decided to select overall process to produce biodiesel is esterification and transesterification process. Solar plant in our project based on the concentrated solar power. I concentrate the sun irradiation to the receiver and transfers the energy from it to the hot fluid which then transfers the heat to the steam turbine. The turbine converts the enrgy to the electricity. Furthermore, biodiesel plant consist of equipment that required electricity for running. Based on the background, our plant is located in Serunya Regency, Central of Kalimantan, the electricity is not supported by the national grid. Therefore, we consider alternative energy to support the plant. In process selection, from three alternative of energy resource we have, our group has decided to select Concentrated Solar Thermal power as electric production The plant on our project diided into two, which are solar elecricity plant and biodiesel. For biodiesel plant, the mass balance and eneergy balance comes from reactor, separator, and heaters. As for solar plant the energy comes from heater, solar heater, and steam turbine. LIST OF CONTENTS EXECUTIVE SUMMARY .................................................................................................... 1 CHAPTER I ............................................................................................................................ 4 INTRODUCTION ................................................................................................................... 4 1.1 Background ............................................................................................................. 4 1.2. Theory ...................................................................................................................... 7 1.2.1 Biofuel .............................................................................................................. 7 1.2.2 Biodiesel ........................................................................................................... 7 1.2.3 Solar Power .................................................................................................... 8 1.2.3 Concentrating Solar Panel .......................................................................... 10 1.3 Preliminary Analysis ............................................................................................ 12 1.3.1 Raw Material Analysis .................................................................................. 12 1.3.2 Market and Capacity Analysis ..................................................................... 21 1.3.3 Plant Location Analysis ................................................................................ 28 4. CHAPTER 2 PROCESS SELECTION ...................................................................... 32 5.1. Production of Biodiesel ......................................................................................... 32 2.2.1. Black Box ....................................................................................................... 32 2.2.2. Process Selection ........................................................................................... 35 2.2.3. Process Description ....................................................................................... 38 5.2. Production of Electricity ...................................................................................... 44 2.2.1. Black Box ....................................................................................................... 44 2.2.2. Alternative Process of Solar Power Plant ................................................... 45 2.2.4. Process Selection ........................................................................................... 50 2.1.4. Hierarchy of Decision ............................................................................................. 56 CHAPTER III ....................................................................................................................... 61 MASS AND ENERGY BALANCEq ................................................................................... 61 BIODIESEL ................................................................................................................... 61 3.2 Energy Balance ............................................................................................................. 64 5. CHAPTER 4 PROCESS CONCLUSION ................................................................... 70 CHAPTER I INTRODUCTION 1.1 Background Energy is the single most important resource capable of sustaining life on earth. Energy not only is the engine of economic growth but also the cause of important life threatening outcomes (Karbassi et al., 2008). During the past decades worldwide energy consumption has permanently increased due to the growth of human population and industrialization. This increase will mostly be for fossil fuels as fossil fuels make up 86% of the worlds energy supply, which has caused depleting fossil fuel reserves ,which are finite and found only in a few regions of the world. Based on data from the Ministry of Energy and Mineral Resources (ESDM) on January, 2008, Indonesia's oil reserve is currently about 9 billion barrels. With a production rate of about 1 million barrels per day, it is expected to be exhausted in about 20 years. On the other hand, combustion of fossil fuels contributes most to emissions of greenhouse gases (GHG), which lead to atmospheric pollution and global warming. Thus, the search for an alternative energy sources has become very necessary. The strong interest in liquid biofuel is due to the fact that it can be used as a supplement, or alternative, to gasoline or diesel fuel derived from petroleum fossil fuel (Ghobadian, 2012a).About 100 years ago, Rudolf Diesel invented diesel engine which worked with vegetable fuel (Knothe et al., 2005, Najafi et al., 2009). Over time with entrance of oil as new and cheap fuel, tendency to this fuel increased. Vegetable oils such as canola oil have been used in diesel engines. When it is used in IC (internal combustion) engines, this oil owes some problems such as low ignition quality. All oils have high viscosity and need specific injection pumps and injectors. Mixing this oil with oil derivatives, could partially solve the high viscosity problem. Biodiesel is a renewable energy derived from vegetable oil and animal fats by transesterificationwith methanol and is widely adopted in many countries around the world as an alternative form of energy resource. It has been found to be a very good substitute for petroleum diesel with several advantages such as lower toxicity, higher flash and fire points than the petroleum diesel meaning that they are less flammable hence they are safer to handle, better biodegradable and higher lubricity than the petroleum diesel which means that an engine run on biodiesel will be less prone to wear and will last longer (Alnuami dkk, 2008). The high cost of biodiesel is a major setback to its commercialization. And is mainly due to the high cost of raw materialsits the production. Therefore, identifying the right and readily available material that will give good biodiesel yield with good fuel properties and performance dynamic efficiency is very important. Production of biodiesel have the full support of the Indonesian government. In the National Energy Policy, the government expects that by 2025 the use of biofuels will account for 5 percent of the national energy mix. Biodiesel production in Indonesia, which currently reaches 2 million kiloliter (KL) per year will be increased to 5 million kiloliters per year. (Kemenperind, 2015) The consumption of diesel oil in Indonesia in 2005 reached an average of 70,000 kilo liters per day, equivalent to 26 million kiloliters per year. On such conditions as the consumption of diesel fuel when oil production in the country does not reach 13 million kiloliters per year, making it necessary to import diesel oil more than 13 million kilo liters. Considering the increasing of diesel oil consumption, especially in the transport sector, the estimated volume of diesel oil imports will continue to increase if there is no policy of diversification of diesel fuel substitution, such as biodiesel. On the other hand, the sun provides enough energy to supply the worlds energy needs for one year. In one day, it provides more energy than the worlds population could consume in 27 years. The energy is free and the supply is unlimited. All we need to do is find a way to use it. The largest solar electric generating plant in the world produces a maximum of 354 megawatts (MW) of electricity and is located at Kramer Junction, California. Indonesia is crossed by the equator, granting abundant amount of energy source with considerably high intensity (up to 4.8 kWh/ m2/ day). But, the development of off-grid solar electricity has not yet initiated. The phenomenon of Solar electricity technology is simple- converts sunlight directly into electricity using photovoltaic cells. Solar electricity systems can be on grid, off grid or hybrid, depending upon choice, flexibility and budget. Similarly, can be installed on rooftops, integrated into construction designs, or scaled up to megawatt scale power plants. Solar elctricity systems can also be used in conjunction with concentrating glasses or lenses for large scale integrated power. Solar radiation is not a very consistent and reliable source because of daily and seasonal variations. However, It does carry the ability to provide maximum efficiency during peak day time hours. Therefore, solar electricity systems are assumed to work well under off-grid technology applications, and in those areas where cost of electricity generation is higher. After mapping solar irradiation (the amount of available solar energy on the ground surface over a specified time, expressed as kWh/m2 or MJ/m2) in Indonesia using artificial neural network method (a mathematical method that is used to predict the output by considering several inputs), the solar irradiation values are divided into three classifications: yellow (below 4.9 kWh/m2), orange (4.9-5.25 kWh/m2), and dark brown (above 5.25 kWh/m2).

Figure 1.1 Solar Irradiation at Indonesia As shown in Fig.1.1, not all cities receive equal distribution of solar energy due to continuously high humidity. However, it is clear that most islands in Indonesia have high potential of global solar irradiation ranging between 4.6 kWh/m2 and 7.2 kWh/m2. The solar irradiation map indicates that Indonesia is suitable place to generate electricity using solar electricity system. The aims are: 1. Reducing the energetic dependence of nations with respect to fossil resources acting as stabilizing factors in a global market environment; 2. Reducing the global pollution by less CO 2 emissions on a lifecycle basis; 3. Reducing the local pollution in terms of CO, CO 2 , sulfur and fines particles; 4. Enabling recycling various potentially energetic industrial and domestic wastes, as cooking oil and fats, as well as agricultural residues; 5. Ensuring a better balance between industry and agriculture, creating new jobs in rural areas and sustainable economic growth.

1.2. Theory 1.2.1 Biofuel Biofuel is one of the alternative fuel that projected to substitute the use of convensional fossil-fuel, the resources of biofuel is come from organic matters. Biofuel is fuel that that cn be synthesized from renewable and sustainable resources, plants (Prastowo, 2008) . the resources can be obtained from palm, rubber tree, coconut, soy, and other kind of plants that contain high concentration of Oleic Acid . because the resources was part of food commodities, the making-of biofuel directed to use non-food commodities as the resources (Prastowo 2008). Biofuel contain less pollutant compared to fossil fuel. This happen because the plants used as the resources, consume CO2 from atmosphere for its photosynthesis process, so we could say that biofuel has a closed CO2 cycle. There were more than one generation of biofuel that developed nowadays. One of the First-Generation biofuel is biodiesel or in Indonesia often called bio-solar. 1.2.2 Biodiesel Biodiesel is mono alkyl ester coming from the esterification and/or tranesterification reaction between free fatty acid and/or triglyceride with methanol. Biodiesel or alkyl ester have `similar properties with solar, even come with better cetane number. (Knothe,2009). Biodiesel come from transesterification reaction, has high cetane number, but it has hivh viscosity, high cluod point, weak oxidation stability, and rich of carboxylic acid and Oxygen (Immer et al., 2010) . the higher the content of Oxygen will lowering the energy density, beside that, biodiesel can cause damage to polymer within the vehicle engine. As stated before, this cause biodiesel cannot be fully adapted yet for today vehicle. So to overcome the possible problem, biodiesel should be mixed with conventional diesel (B10, 10% v/v biodiesel or B20, 20% v/v iodiesel). (ocha et al. , 2012) 1.2.3 Solar Power There are two ways by which we can convert solar energy into electrical energy. These are as shown in figure 1.2.

Figure 1.2. Ways of converting solar energy into electrical energy Solar thermal: The solar collectors concentrate sunlight to heat a heat transfer fluid to a high temperature. The hot heat transfer fluid is then used to generate steam that drives the power conversion subsystem, producing electricity. Thermal energy storage provides heat for operation during periods without adequate sunshine.

Figure 1.3 : Solar thermal Solar Photovoltaic: Another way to generate electricity from solar energy is to use photovoltaic cells; magic slivers of silicon that converts the solar energy falling on them directly into electricity. Large scale applications of photovoltaic for power generation, either on the rooftops of houses or in large fields connected to the utility grid are promising as well to provide clean, safe and strategically sound alternatives to current methods of electricity generation.

Figure 1.4: Solar Photovoltaic 1.2.3 Concentrating Solar Panel Concentrating Solar Power A concentrating solar power (CSP) system can be presented schematically as shown in Fig. x. All systems begin with a concentrator; the various standard configurations of trough, linear Fresnel, dish and tower have been introduced in Chapter 1, and are addressed in detail in later chapters. There is a clear distinction between the line-focusing systems which concentrate solar radiation by 50100 times, and the point-focus systems that concentrate by factors of 500 to several thousand.

Figure 1.5 Schematic representation of the component parts of a solar thermal power system. The concentrated radiation must be intercepted by a receiver which converts it to another form, typically thermal energy. The currently dominant trough-based CSP systems use receivers that are single steel tubes covered by a glass tube, with the annular space evacuated to reduce convection heat losses. Another commonly used option is to arrange multiple tubes to form cavity shapes (either line- or point-focus). Alternatively, volumetric or direct absorption receivers aim to have the radiation absorbed by surfaces directly immersed in the working fluid. This can be done by having a window in front of a cavity containing an absorbing matrix which the fluid passes over. Later chapters present details on possible receiver types for the various concentrator technologies. After the receiver, there are two options: either the energy is further converted to the fi nal form desired (such as electricity), or it is transported to another location for final conversion. It is possible that the power cycle is built integrally into the receiver unit (Stirling engines, for example). Solid state (semiconductor material) conversion devices such as concentrating photovoltaics and thermoelectric converters also lead to receivers built from the devices themselves. If power conversion is carried out remote from the receivers, the collected thermal energy is carried away in a heat transfer fluid (HTF). For the trough plants built to date, this is predominantly a type of oil chosen for its transport properties as well as thermal stability. Direct steam generation has been used with all concentrator types and has the advantage that the HTF and power cycle working fluid are one and the same, eliminating the need for a heat exchanger. Molten salt as HTF was pioneered in tower systems and has also been introduced for troughs. It has the advantage that the HTF is then also a favorable energy storage medium. Use of air as a HTF has also been demonstrated, and chemical reaction systems are under development as heat transfer mechanisms. Choice of the transport path provides the option of thermal energy storage (TES) in the intermediate thermal form before going to final conversion to electricity. The current commercially dominant approach is to use molten salt in high temperature insulated tanks. Chapter 11 covers thermal energy storage options in detail. There is also the option of designing an energy storage system after conversion to electricity; however, electricity storage approaches are not integral to the CSP system itself but rather are independent systems that could be applied to any form of electricity generation and are not addressed in this book. The final stage in a CSP system is electric power generation. The dominant approach here is steam turbines, with Stirling engines, organic Rankine cycles, Brayton cycles and photovoltaics also successfully proven. The efficiency of each subsystem can be defined as the ratio of energy out to energy in. The overall solar-to-electric conversion efficiency for the CSP system (system) is the product of the various subsystem efficiencies (concentrator/ optical, receiver, transport, storage and conversion): system = optical receiver transport storage conversion [A] These can be considered at a particular instant or averaged over a timescale such as a day or a year. Alternative naming of these efficiencies are frequently seen, and subsystems can be further grouped or subdivided according to what is being analyzed. The driving principles behind the development of CSP1 systems are that: final conversion of collected thermal energy to electricity is more efficient if the energy at the conversion subsystem is available at a higher temperature; countering this, energy losses from receivers increase with temperature, but can be reduced by reducing the size of the receiver via concentration of the radiation; cost factors and material limits sometimes determine that the optimal operating conditions must be lowered. This chapter reviews the various fundamentals that contribute to these principles and lead to the design of systems that seek to maximize overall conversion efficiencies. The chapter ends with an introduction to the key aspects of the economic analysis of CSP, since ultimately it is the cost of production of energy that matters most. Cost of energy depends strongly on the installed cost per unit of generating capacity plus also the level of solar resource and financial parameters. It is thus affected by both the efficiency of systems and their cost of construction. Ultimately the design process is one of thermo-economic optimization (see, for example, Bejan et al., 1996). 1.3 Preliminary Analysis 1.3.1 Raw Material Analysis There are different potential raw materials for biodiesel production. Currently, edible oils are the main resources for world biodiesel production. However, there are many reasons for not using it. Edible plant oils Biodiesel has been predominantly (more than 95 %) produced from edible vegetable oils (biodiesel first generation) all over the world, which are easily available on large scale from the agricultural industry. Currently, biodiesel is mainly prepared from rapeseed in Canada, soybean in US, sunflower in Europe and palm in Southeast Asia . However, continuous and large scale production of biodiesel from edible oils has recently been of great concern because they compete with food materials. Knowing that, nearly 60 % of humans in the world are malnourished. The largest biodiesel producers were the European Union, the United States, Brazil, Indonesia, with a combined use of edible oil for biodiesel production of about 8.6 million tons (7.8 million hectares were used ) in 2007. The estimated increase in edible oil use for biodiesel production was 6.6 million tons from 2004 to 2007, which would attribute 34 % of the increase in global consumption to biodiesel. Between 2005 and 2017, biodiesel use of edible oils is projected to account for more than a third of the expected growth in edible oil use, which means rise of biomass price, increase in water requirement and problem in water availability, and particularly, more land somewhere in the world will be converted into farmland, thereby releasing GHG emissions. Because of these disadvantages, researchers have sought other renewable resources for biodiesel production. Non-edible plant oils Technologies are being developed to exploit cellulosic materials for the production of biodiesel (biodiesel, second generation) such as leaves and stems of plants, biomass derived from waste, and also, oils seeds from non-edible plants. Non-edible biodiesel crops are expected to use lands that are largely unproductive and those that are located in poverty stricken are a sand in degraded forests. Moreover, non-edible oil plants are well adapted to arid, semi-arid conditions and require low fertility and moisture demand to grow. Added to this, non-edible oils are not suitable for human food due to the presence toxic components in the oils. For all these reasons, the use of non-edible oils as raw material is a promising way in biodiesel production. There are a large number of oil plants that produce non-edible oils. From a list of 75 plant species containing oil in their seeds or kernels, 26 species were reported by Azam et al., as potential sources for biodiesel production. The important non edible oil plants are jatropha, karanja, tobacco, mahua, neem, rubber, sea mango, castor, cotton. Of these feedstocks, jatropha, moringa and castor oils are the most often used in biodiesel production. In Algeria, Castor oil is findable but it is not very current. Added to this, the biodiesel produced from castor oil present a very elevated value of viscosity compared to the value imposed by the American norm (ASTM D6751) and the European norm (EN14214). Moringa was planted in Mascara (359 km West of Algiers), where the climate of the region was not really suitable for its development. Also, moringa comes just barely be planted in Tamenrasset (1970 km South of Algiers) and in the Institut Technique de lArboriculture Fruitire ITAF (Algiers) but its potential of development is not yet put in evidence. Jatropha has been planted in Adrar (1543 km South of Algiers) as part the JatroMed project which has as purpose the cultivation of jatropha to check its potential development in Algeria. JatroMed involves five countries from the Mediterranean region: Greece (project coordinator), Italy, Egypt, Morocco and Algeria. The non-edible oils plant are called to solve the problem of competition with food production. However, the problem of water requirement, water availability, and mainly, the quantity of GHG generated by the great rate of exploitable land could not be solved using this raw material. Used edible oils There were several end-uses for used edible oil (commonly called Waste Cooking Oil, WCO), such as the production of soaps or of energy by anaerobic digestion or thermal cracking. However, because of the poor quality of soap produced from WCO, a large amounts of WCO are illegally dumped into rivers and landfills, causing environmental pollution. Hence the management of such oils and fats pose a significant challenge because of their disposal problems and possible contamination of the water and land resources. The production of biodiesel from WCO to partially substitute petroleum diesel is one of the measures for solving the twin problems of environment pollution and energy shortage. Also, in order to reduce the cost of biodiesel production, WCO would be a good choice as raw material since it is cheaper than virgin vegetable oils and other feedstock. The used edible oil is categorized by its Free Fatty Acid (FFA) content. If the FFA content of WCO is < 15 %, then it is called yellow grease; otherwise, it is called brown grease.The amount of WCO generated in each country is huge and varies depending on the use of vegetable oil. Microalgae Microalgae as a raw material for biodiesel (biodiesel third generation) has been reviewed extensively in recent years. They are photosynthetic microorganisms that convert sunlight, water and CO2 to algal biomass. Microalgae are classified as diatoms (bacillariophyceae), green algae (chlorophyceae), golden brown (chrysophyceae) and blue green algae (cyanophyceae). The microalgae have long been recognized as potentially good sources for biofuel production because of their high oil content (more than 20 %) and rapid biomass production. Algae biomass can play an important role in solving the problem between the production of food and that of biofuels in the near future. The cultivation of microalgae does not need much land as compared to that of terraneous plants. Due to their high viscosity (about 1020 times higher than diesel fuel) and low volatility, microalgaedo not burn completely and form deposits in the fuel injector of diesel engines. The transesterification of microalgal oils will greatly reduce the original viscosity and increase the fluidity. Animal fats Animal fats used to produce biodiesel include tallow, choice white grease or lard, fish fat (in Japan) and chicken fat. Compared to plant crops, these fats frequently offer an economic advantage because they are often priced favorably for conversion into biodiesel. Animal fat methyl ester has some advantages such as high cetane number, noncorrosive, clean and renewable properties. Animal fats tend to be low in FFAs and water, but there is a limited amount of these oils available, meaning these would never be able to meet the fuel needs of the world. Table 1.1 Property comparison of chicken fat, Methyl esters, and diesel

Considering some reason, we eliminate algae and animal fats as the resource of our biodiesel plant. For algae, The major disadvantage of biomass production from algae is that production is still far to expensive to be commercially viable, and the cost of various algae species typically varies between $510 per kilogram. The industry is still testing a wide variety of methods for growing algae; currently the most popular are open-pond systems, that in 2008 accounted for 98 percent of commercial algae biomass production. These systems are relatively cheap compared to some other methods for growing algae (such as bioreactors) but they have some serious flaws like the possibility of contamination by native algae species, evaporation, viral infection, and in most cases produce lower energy density algal oil. Another disadvantages are: 1) produces unstable biodiesel with many polyunsaturates, 2) biodiesel performs poorly compared to its mainstream alternative, and 3) it is relative new technology. Other limitations include the low concentrations of free CO2 that are required for peak algal growth and that algal grazers are a significant, but somewhat ignored problem (Schenk et al., 2008). The difficulties in efficient biodiesel production from algae are not from the extraction of the oil, but in finding an algal strain with a high lipid content and fast growth rate that is not too difficult to harvest, and a cost-effective cultivation system (type of photobioreactor) that is best suited to that strain (Demirbas & Demirbas, 2010). While animal fats, , however, has its own disadvantage when used for producing biodiesel. Animal Tallow has High Cloud Point. Biodiesel produced from Animal Tallow tends to crystallize out at much higher temperatures than biodiesel derived from Plant oils, because of the level of saturation present in Animal Tallow. Animal Tallow has High Cloud Point. Biodiesel produced from Animal Tallow tends to crystallize out at much higher temperatures than biodiesel derived from Plant oils, because of the level of saturation present in Animal Tallow. Because it contains high amounts of saturated fat, biodiesel made from this feedstock tends to gel, limiting widespread application of this type of fuel, particularly for winter-time use (Wen et al. 2006). Beside that the availability of this feedstock in our plant location is still doubtful since our plant is located in remote area and we have to save the transportation cost in delivering feedstock to our plant Therefore, we use Jathropa as our source in making biodiesel through transesterification reaction, because, in comparing edible and non-edible materials, that is; oil palm and soybean oil as edible oil with jatropha and waste cooking oil as non-edible oil, it could be seen from the result that non edible oils are more suitable to produce biodiesel because they are not competitive with the food material, this will preserve the food sources alone even though biodiesel from edible oils have properties closer to standard diesel properties. Also, biodiesel from edible oils are not economical Compared with non-edible oils. Jatropha and waste cooking oil are more readily available than oil palm and soybean oils. Jatropha appears to have several advantages as a renewable diesel feedstock, because it is non-edible and can be grown on marginal lands; it is potentially a sustainable material for biofuel production. The high oil content of Jatropha curcas indicates that Jatropha curcas is suitable as non-edible plant oil feedstock in oleo chemical industries. Jatropha has been planted in several arid regions, in these regions it only yields about 0.5 ton per hectare. The seeds contain about 30% oil. Biodiesel from Jatropha curcas so obtained were found to be comparable to those of fossil diesel conforming to the American and European standards. The cost of biodiesel is a great hindrance to its widespread use as it is very high, almost twice that of petroleum diesel. This high cost is influenced by the cost of raw materials, Cost of processing i.e. transesterification and purification, and market value of the by-products. Of all three mentioned above, the cost of the raw material holds the highest stake in the determination of the price of biodiesel. The cost of raw materials amount to about 80% of the total operating cost, this is due to the high cost of the feedstock oils. This high cost of feedstock oils is in turn attributed to the unavailability of sufficient agricultural land for the cultivation of the oil seeds for biodiesel production as the food materials for food production. More so, some of these oil seeds like the oil palm are edible while others are also used in various aspects of the chemical industry like the soap industry, hence the demand for these oil seeds are high as against its supply. Jathropha curcas oil and waste cooking oil which is non-edible oils are very cheap and economical materials in the production of biodiesel. But, its hard to find the sufficient feedstock of waste cooking area in our plant location since it is in the remote area. We should build the plant near the city with many fast food restaurants to make it feasible. So the best raw material for our biodiesel plant is Jatropha Curcas. Comparison 1 : Properties of Vegetable Oil The vegetable oils that are used for the production of biodiesel have some fuel related properties. Some of these properties are found in table 1.2 Table 1.2 Oil Properties

Table 1.3 Some Chemical properties of Oil

Table 1.4 Fatty Acid distribution of the Oil (% wt) Comparison 2 : Fuel Properties of Biodiesel (as compared to Petroleum Diesel) The properties of biodiesel are close to diesel fuels. Biodiesel is characterized by determining its viscosity, density, cetane number, cloud and pour points, characteristics of distillation, flash and combustion points, higher heating value, etc. Viscosity The viscosity of a liquid is a measure of its resistance to flow; this is a very important property of a diesel fuel because it affects the engine fuel injection system predominantly at low temperatures. A highly viscous fuel will result in poor atomization hence a loss of power of the engine and production of smoke. As shown in the table 1, biodiesel is slightly viscous but their viscosities are still close to that of the petroleum diesel. This is an advantage of biodiesel over its source oils. Density The density of diesel fuels is another important property of the fuels that affects the fuel injection system, density is usually measured at 15 C. Density of biodiesel is the weight of a unit volume of fluid while the specific gravity is the ratio of the density of a liquid to the density of water. The fuel injection equipment meters the fuel volumetrically and high densities translate into a high consumption of the fuel. From table 1, it can be seen that biodiesel has densities between 0.860g/cm3 and 0.897g/cm3 at 15 C which is higher than that of the petroleum diesel, however this high density can be said to make up for the low volumetric energy content of biodiesel. Cetane Number The cetane number of a fuel is a measure of the ignition quality of the fuel, the higher the cetane number the better the ignition quality. Flow; this is a very important property of a diesel fuel Standards for biodiesel. On the basis of ignition quality, biodiesel can be said to be better than the petroleum diesel because they have cetane numbers higher than that of the petroleum diesel, this high cetane number is due to higher oxygen contents. This means that they will burn smoothly and with less noise in a diesel engine than petroleum diesel. Flash and Fire points Biodiesel's have higher flash and fire points than the petroleum diesel meaning that they are less flammable hence they are safer to handle. However, biodiesel has worse oxidation stability than petroleum diesel and will deteriorate under prolonged storage due to oxidation in the presence of air. Lubricity and cold flow Biodiesel's have higher lubricity than the petroleum diesel which means that an engine run on biodiesel will be less prone to wear and will last longer. However, the major property of biodiesel, which hampers its use as a neat fuel (B100), is the cold flow property otherwise known as the low temperature flow property. Biodiesel's have been reported to have relatively high cloud and pour point. The cloud point is the temperature at which is the fuel starts toform crystals, with further decrease in temperature these crystals increase in size and quantity until the fuel gels and does not move again. The cloud point is of more importance because it indicates the onset of filterability problems of the fuel in the fuel filter equipment. Table 1.5 Biodiesel Properties

1.3.2 Market and Capacity Analysis The market analysis of biodiesel is a section that presents information about the commercial market and also to know about the targeted customers in that market. The result of market analysis can be used to determine design capacity of the plant. As we know, the society are now more concern about green, eco-friendly fuel that doesnt emit harmful gases. The awareness are based on the reality that the emissions coming from vehicles fuel combustion have spoiled the natures stability, which one of the impact is the global climate change. That increase of awareness have driven many countries to start applying policies regarding the shifting from petroleum based energy to the more environmental friendly energy. One of the policy is using biodiesel as a blending material on fossil fuel, such as diesel fuel, which purpose is to increase the fuels cetane number so that its combustion will be more complete and the emissions will be minimized. As for Indonesia, since a decade ago, the government have started to encourage the domestic biodiesel production and consumption. As per April 2015, Indonesias government through the Ministry of Energy and Mineral (ESDM) has increased the blending percentage target for fossil fuel from 10% to 15%. That increase in blending percentage target will automatically increase the biodiesel demand in Indonesia. According to data from Ministry of Energy and Mineral (ESDM) on 2006, the total consumption of diesel fuel in transportation and industry sector can be seen on table xx below. Year Transportation Consumption (kL) Industry Consumption (kL) Combined Consumption (kL) 2005 11,791 8,320 20,111 2006 14,411 8,570 22,981 2007 12,669 8,827 21,496 2008 13,101 9,091 22,192 2009 12,949 9,364 22,313 2010 13,522 9,645 23,167

By considering the economy growth of Indonesias citizen on 2015, which value is as much as 5.5% according to Asian Development Bank, we could do an estimate about the demand for diesel fuel in those two sectors the next 10 years ahead. The estimation can be seen on Table xx and Figure xx below, from which we could see that the trend for diesel fuel demand in Indonesia is linearly increasing annually. Year Transportation Consumption (kL) Industry Consumption (kL) Combined Consumption (kL) Combined Consumption (ton) 2011 14,266 10,175 24,441 20,335,066 2012 15,050 10,735 25,785 21,453,495 2013 15,878 11,326 27,204 22,633,437 2014 16,751 11,948 28,700 23,878,276 2015 17,673 12,606 30,278 25,191,581 2016 18,645 13,299 31,944 26,577,118 2017 19,670 14,030 33,701 28,038,859 2018 20,752 14,802 35,554 29,580,997 2019 21,893 15,616 37,510 31,207,951 2020 23,098 16,475 39,573 32,924,389

20,000,000 22,000,000 24,000,000 26,000,000 28,000,000 30,000,000 32,000,000 34,000,0002010201220142016201820202022Biodiesel Demand (ton)Year From that estimation, we can multiply each of them with 0.15 factor (from the blending percentage target being set by the government) to get the annual demand for biodiesel in Indonesia. The estimation for annual demand of biodiesel in Indonesia could be seen on Table xx below. Year Biodiesel for Transportation (kL) Biodiesel for Industry (kL) Biodiesel Combined (kL) Biodiesel Combined (ton) 2011 2,140 1,526 3,666 3,050,260 2012 2,258 1,610 3,868 3,218,024 2013 2,382 1,699 4,081 3,395,016 2014 2,513 1,792 4,305 3,581,741 2015 2,651 1,891 4,542 3,778,737 Year Biodiesel for Transportation (kL) Biodiesel for Industry (kL) Biodiesel Combined (kL) Biodiesel Combined (ton) 2016 2,797 1,995 4,792 3,986,568 2017 2,951 2,105 5,055 4,205,829 2018 3,113 2,220 5,333 4,437,149 2019 3,284 2,342 5,626 4,681,193 2020 3,465 2,471 5,936 4,938,658 Average 4,556,816

From data in the table above, we could calculate that the percentage of biodiesel demand for each sector is 42% for industry sector and 58% transportation sector. From that percentage, the average annual demand for each sector could be seen on table xx below. Annual Demand in Industry Sector (ton) Annual Demand in Transportation Sector (ton) 1,897,116 2,659,700

The total demand of biodiesel in Indonesia has reached 4.5 million ton per year, while the domestic production of biodiesel in Indonesia was still at 1.3 million ton per year according to ESDM data on 2006. From that data, by assuming that the domestic production biodiesel stays the same, there is a gap as much as 3.2 million ton per year of biodiesel demand that is still not covered by the domestic supply. By using the percentage of demand on transportation and industry sector, 48 and 52% accordingly, and assuming that the domestic production of biodiesel stays the same, then we could calculate the demand for biodiesel on each of these sector which could be seen on Table xx below. Domestic Supply Biodiesel for Industry Domestic Supply Biodiesel for Transportation Deficit Supply for Industry Deficit Supply for Transportation 541,222 758,778 1,355,894 1,900,923

From that data, we could see that the transportation sector consumes bigger portion of biodiesel, which makes it reasonable enough to choose the transportation sector as our main marketing target. But considering the location of our plant which will be located in a remote area of Kalimantan, it may not be the best option because there will be not so many vehicles in such location and it is not feasible to ship the biodiesel to Java or Sumatera. It is way wiser to choose the industry sector as the marketing target for our biodiesel product, since there are quite a few industries located in Kalimantan. According to data from Ministry of Industry, Kalimantan has about 542 ha industrial area or equal to 1.83% of total industrial area in Indonesia. Furthermore, the type of industries in Kalimantan are generally a huge energy and petrochemical industries, which must have a big demand on diesel fuel for their electricity generators. That could be our opportunity to market our biodiesel product as blending material for their diesel fuel. The distribution of industrial area in Indonesia and the estimation of biodiesel annual demand for industry in each of these industry area could be seen on Table xx dan xxx below. Location % Sumatera 14.96 Java 75.89

Kalimantan

1.82 Sulawesi 7.33

Location Not Covered Demand for Biodiesel (ton/year)

Kalimantan

24,677 Sumatera 202,842 Java 1,028,988 Sulawesi 99,387

According to the data highlighted above, we can see that there are still about 24,677 ton biodiesel demand which is still not covered per year. That will be our opportunity to market our biodiesel product in Kalimantan. Since our plant is new and the scale will not as big as the commercial plant in general, we will only take about 2% of that not covered demand as our plant capacity which value is as much as 493.55 ton/year. There are 365 days in a year, and we decided to have maintenance for as much as three times per year and duration for each maintenance will be 10 days. Maintenance is crucial, and it needs to be conducted regularly in order to keep the best performance out of our plant. With that, our plant will have a total 335 operating days and production per day as much as 1.47 ton/day. The waste produced by our plant, such as glycerol and seeds pulp will be sold to the 3rd parties. Since our plant will also produce electricity, we need to find a market to sold that electricity we produced. Below is the analysis for our electricity market. Number of household and area Seruyan district

To capture an overview of electricity requirement for Seruyan district we refers to Table .sekian above that is representing the number of household in the district that is 146,914. Also, information extracted from the data, we get the average household in one house is 3.54. Refers to these data, we are able to get the number of house by dividing the number of household to the number of average household in one house, that is 41,501. Secondly, the data provided by various resource give us an average of the minimum requirements of electricity for every house is 540 W. By multiplying the number of house and energy needed for very house we get the result 22,41 MW for Seruyan district. The data given before, Seruyan has deficit 30% of energy. Therefore, the energy that needed to be fulfilled is 6,72 MW. 1.3.3 Plant Location Analysis In order to determine the location for our plant, we should consider some important aspects that will influence the production activity of our plant in the time of normal operation later. There were some consideration that we have in choosing our location, such as raw material availability, water avalbility, power distribution, land availability labor and transportation access for supply and distribution line. The location are in Seruyan, Central Kalimantan, with an area of 16.404 km2 , 11,6% of the are of Central Kalimantan. Main reason we choose the location is related to space available in the region, raw materials availability and transportation line. Our raw material consist of : Jathropa Curcas , Methanol.

Figure 1.3.1 Map of Seruyan (source : seruyankab.go.id) 1.3.3.1 Raw material Avalaibility a. Jathropa Curcas

Indonesia is one of the highest resource of Jathropa. Based on the survey, the availability in was 176.000 hectare. The fertile soil in Kalimantan was very suitable for jathropa to grow, in Central Kalimantan Jathropa has been produced in 20.000 hectare scale. b. Methanol

The source of methanol we used in our plant will beprovided by PT.KMI (Kaltim Methanol Industri) PT. Kaltim Methanol Industri is a petrochemical industry producing methanol located in industrial area of PT. Kaltim Industrial Estate (a subsidiary company of PT. Pupuk Kalimantan Timur) Bontang, about 110 kms to the north of Samarinda city, the capital of East Kalimantan province. PT. Kaltim Methanol Industri (KMI) was established under The Republic of Indonesia Law of January 25th, 1991 as a Domestic Investment Company (PMDN). This status was, on December 9th, 1997, changed to Foreign Investment Company (PMA) with Nissho Iwai Corporation as the largest shareholder (85%). PT. Humpuss owns 10% and Daicel Chemical Singapore Pte Ltd owns another 5% of the share. The merging of Nissho Iwai Corporation and Nichimen Corporation becoming Sojitz Corporation on April 1st, 2004 made Nissho Iwai Corporations share handed over to Sojitz corporation. Methanol plant utilizes natural gas, as its raw material, from Badak Gas Field Center supplied by Production Sharing Contractors of Pertamina, namely Total Fina Elf Indonesie, Vico Indonesia and Chevron. The natural gas was first piped on January 23rd, 1997 continued with plant commissioning and then started up on March 31st, 1997. Following the first drop of raw methanol on February 29th, 1998 and Pure Methanol Grade AA (purity min 99,85%) on the March 8th, 1998, the plant commercially began its operation obtaining the installed capacity of 660.000 MTPY on July 29th, 2000. The strategic port location that lies at latitude 00 10-34 north and longitude 117-20-36 east has made PT. Kaltim Methanol Industri accessible to its customers, particularly those in Asia Region. To support methanol loading activities, KMI has its own jetty facilities under the Minister of Transportation Decree No.SK-52/AL.003/PHB/1998, ISPS Code No. 02-0014-DV. The jetty has a capacity of 30.000 DWT with the length of 206 meters and the pool of 11,50 m LWS. It has two loading arms whose capacity is 1300 MT/hour each. The technology used is methanol synthesis process with low pressure licensed by Lurgi Germany. Its operation is supported by 200 workers skilled in their fields. The product of PT.Kaltim Methanol Industri has been marketed in various places both domestic and overseas. 70% of the product overseas is marketed by Sojitz Corporation, and the remaining 30% of the product is marketed in Indonesia by PT. Humpuss. Methanol purchasers are industries such as formaldehyde, acetic acid, MTBE and others that use methanol as their raw material. 80% of the methanol purchasers in Indonesia are industries in the fields of formaldehyde that produce adhesives for plywood and other wood processing industries. a. Water Avaailability

Our plant will be located in land near the riverside. Which mean there were be plenty source of fresh, clean water b. Power Avilability

Because our plant concept was sustained, independent, the power needed to run our plant was supplied using the solar electricity. The available electricity evenly distributed by our plant to the people in the region . c. Labor

Based on the data taken from Seruyans government website, population in Seruyan reached 146.914 person counted in 2012, spread in 14 ditricts, 3 sub-district , 97 village. Acoording to gender, male consist of : 78.984 person and women 67.930 person. If we grouped by age, widely seruyan population is in the 25-29 age group (18.622 person) followed by children at the age 0-4 years old ( 16.103 person) , as stated, seruyan population dominated by 0-39 age group. This condition of course should be well anticipated from foodstock, education , health, and other basic services. The ratio of the working population or employment is the ratio of the working population to the labor force. Employment opportunities is the relationship between labor force with the ability of employment. Added workforce should be matched by investments that can create employment opportunities. Thus, it can absorb the increase of the labor force. From the table provided below, it appears that there were significant increment in number of people work in Seruyan. Table 1.3.1 Workforce ratio Comentary 2008 2009 2010 2011 2012 Working 46.238 47.740 62.639 72.346 63.722 Find a Job 1.608 1.743 2.925 1.787 2.649 Total 47.846 49.483 65.564 74.133 66.371 Workfoce ratio 0,97 0,96 0,96 0,97 0,96

4. CHAPTER 2 PROCESS SELECTION 5.1. Production of Biodiesel 2.2.1. Black Box According to what we have stated on Chapter 1, we are going to establish a biodiesel plant. For that plant, we decided to use jatropha (Jatropha curcas L.) seeds, methanol, hydrochloric acid, and sodium hydroxide as our main raw material. Figure 2.1 below shows us the black box for common biodiesel production plant. OVERALLPROCESSJatropha SeedsHydrochloric AcidSodium HydroxideMethanolFatty Acid Methyl EstersGlycerolFigure 4.1. Black Box Diagram for the Biodiesel Production (Source: Authors Personal Data) The common process of biodiesel production plant is generally consist of several units, they are: raw materials preparation unit, main reaction unit, product purification unit, byproduct purification unit, and methanol recovery unit, which illustration can be seen on Figure 2.2. Raw Material Preparation UnitRaw MaterialsMain Reaction UnitProduct Purification UnitMethanol Recovery UnitByproduct Purification UnitBiodieselFigure 4.2. Overall Process of the Biodiesel Production (Source: Authors Personal Data) Each of these boxes are containing other sub-boxes, which represent their related process equipment. The raw materials preparation unit contains the sub-unit of jatropha seeds extraction unit, degumming unit, and filtration unit. The main reaction unit contains the sub-unit of esterification reactor unit and transesterification reactor unit, which each of them consist of the reactor unit, distillation unit, and decantation unit. The product purification unit contains the sub-unit of distillation unit, neutralizing-washing unit, and drying unit. The byproduct purification unit contains the sub-unit of acidulation unit, decantation unit, and distillation unit. The methanol recovery unit contains the sub-unit of distillation. The block flow diagram for each of these units could be seen on the following Figure 2.3, 2.4, 2.5, 2.6, and 2.7. The process flow diagram for our biodiesel are attached on the appendix. ExtractionJatrophaSeedsDegumming UnitPhosphoricAcidDecantation UnitDegummedJatropha OilsSolids Particulate and GumsFigure 4.3. Block Flow Diagram for Raw Material Preparations Unit (Source: Authors Personal Data) Esterification ReactorDegummed Jatropha Oils,HCl, MethanolDistillation Unit #1Decantation Unit #1TriglyceridesMethylEsters-1Methanol-1WaterFigure 4.4. Block Flow Diagram for Main Reaction Unit (Source: Authors Personal Data) Transesterification ReactorTryglicerides,NaOH,MethanolDecantation Unit #2MethylEsters-2GlycerolsFigure 4.5. Block Flow Diagram for Main Reaction Unit (Cont) (Source: Authors Personal Data) Distillation UnitMethyl Esters-2Neutralizing UnitDrying UnitHigh PurityMethyl Ester/BiodieselHCl,WaterMethanol-2WaterMethyl Esters-1Figure 4.6. Block Flow Diagram for Product Purification Unit (Source: Authors Personal Data) Acidulation UnitImpure GlycerolDecantation UnitDistillation UnitPure GlycerolHClFFA,NaCl SaltsMethanol-3,WaterFigure 4.7. Block Flow Diagram for Byproduct Purification Unit (Source: Authors Personal Data) Distillation UnitMethanol-1,Methanol-2,Methanol-3PureMethanolWaterFigure 4.8. Block Flow Diagram for Methanol Recovary Unit (Source: Authors Personal Data) 2.2.2. Process Selection - Process Reaction for Biodiesel Production a. Esterification

Esterification is the process of turning free fatty acids (FFA) into esters by reacting FFA with alcohol. This process runs with the help of strong acid catalyst, such as hydrochloric and hydrochloric acid. This process is best carried out on low temperature condition (120oC maximum) and with excess alcohol at least 1:10 of the oil. This process is suitable for raw materials which have a high FFA content (>3%). The esterification reaction can be seen on figure xx and xxx below.

Figure 4.9. Esterification Reaction Between Fatty Acid and Methanol (Source: Authors Personal Data)

Figure 4.10. Acid Calatyzed Esterification Reaction Mechanism (Source: Authors Personal Data) Figure xxx above shows mechanism of esterification process using acid catalyst, where the initial step is the protonation of the acid to give an oxonium ion (1). The oxonium ion can undergo an exchange reaction with an alcohol to produce intermediate (2). The intermediate can lose a proton to become an ester (3). Each of these step is reversible, but by using a large excess of alcohol, the equilibrium point of the reaction could be directed to the product side (Demirbas, 2007). The conversion of this process is known to be high, but requires more than one day to finish (Marchetti et al., 2005). Freedman and Pryde achieve a conversion of 99% by using 1 mol% of hydrochloric acid and methanol-oil molar ratio of 30:1 at 65oC in 50 hours process time. b. Transesterification

Transesterification is the process of exchanging the alkoxy group of an ester compound by another alcohol (Demirbas, 2007). From this transesterification reaction, the main product will be the alkyl esters and the byproduct will be the glycerol. Methanol is a reactive and low price type of alcohol which often used in this process as the alkyl group donator. This process is usually conducted by using alkali catalyst, such as sodium and potassium hydroxide. That catalyst has a role to speed up and increase the conversion of the reaction. The reaction of transesterification with using alkali catalyst can be seen on Figure xx below.

Figure 4.11. Alkali Catalyzed Transesterification Reaction Mechanism (Source: Authors Personal Data) The first step (1) is the reaction of the alkali (B) with the alcohol, producing an alkoxide and the protonated catalyst. The nucleophilic attack of the alkoxide at the carbonyl group of the triglyceride generates a tetrahedral intermediate (2), from which the alkyl ester and the corresponding anion of the diglyceride are formed (3). The latter deprotonates the catalyst, thus regenerating the active species (4), which is now able to react with a second molecule of the alcohol, starting another catalytic cycle. Diglycerides and monoglycerides are converted by the same mechanism to a mixture of alkyl esters and glycerol. Alkaline metal alkoxides (CH3ONa) are the most active catalysts, since they give very high yields (> 98%) in short reaction times (30 min) even if they are applied at low molar concentrations (0.5 mol%). However, they require the absence of water which makes them inappropriate for typical industrial processes. Alkaline metal hydroxides (KOH and NaOH) are cheaper than metal alkoxides, but less active. Nevertheless, they are a good alternative since they can give the same high conversions of vegetable oils just by increasing the catalyst concentration to 1 or 2 mol%. This process is rather not suitable for raw materials with high FFA content, because the FFA will react with the alkali catalyst to produce soaps (saponification). The soaps formation will decrease the conversion and complicates the separation process. c. Combination Esterification-Transesterification

This process combines the esterification with acid catalyst and transesterification with alkali catalyst to achieve high conversion reaction in a short time. As per what we already know from the preceding explanations, the acid catalyzed esterification has weakness over the reaction time while the alkali catalyzed transesterification has weakness over the high FFA content raw materials. This combination process is suitable for high content FFA raw materials, where the raw material will be esterified first to convert the FFA into alkyl ester and then trans-esterified to convert the triglycerides into alkyl ester. By using this process, problems regarding production of biodiesel from high FFA content raw materials will be no more. It is pretty straight forward to choose between those three options of biodiesel production method, since we already have our raw materials well defined. As per what we have explained before, we use jatropha oils as our main raw material. That jatropha oils are known to have a high content of FFA, which mostly consist of linoleic acid, oleic acid, palmitic acid, and stearic acid (Silitonga et al., 2011). The FFA content of jatropha oils are in a range of 8-15% (Lu et al., 2009; Mythili, 2012). As the explanation before, high FFA content will interfere the completion of alkali catalyzed transesterification process through the formation of soaps. It can be avoided by using the acid catalyzed esterification instead. The acid catalyst will help converting the FFAs into mono alkyl esters, which is biodiesel. Thus, when it comes to handling raw materials with high FFA content, the acid catalyzed esterification is the winner. Although the acid catalyzed esterification have advantages on handling a high FFA raw materials, the reaction rate of acid catalyzed esterification process is slow. It could take days, only to complete one batch reaction. Unlike the acid catalyzed, the alkali catalyzed process have a fast reaction rate, where it only take hours or even minutes to complete one batch reaction. Because each of them has their own trade-offs, the combination of both process hold a good prospect. According to a review journal from John Van Gerpen (2005), it is said that a combination between acid catalyzed and alkali catalyzed process suitable for processing a raw materials with FFA content varying from 7-30%. The acid catalyzed process is well placed on the beginning, so that it could convert the FFAs content in the raw materials before entering the alkali catalyzed process. By doing so, the formation of soaps in the alkali catalyzed process could be effectively minimized. By applying this combination process, the overall conversion of biodiesel will also increase. This combination process is known to have a nearly 99% conversion rate, compared to the alkali catalyzed and acid catalyzed process that only have 500 lenses or mirrors) in large area. The reflected light is directed onto small area tower of heat exchanger or boiler receiver (Figure 2.sekianbawah) that contain fluid. The fluid in the receiver is molten salt to absorb the heat from concentrated sunlight. The characteristic of molten salt that maintains wider operating temperature range in liquid state, ideal heat capture medium, allowing system to operate at low pressure, provides a low-cost medium to store thermal energy, its operating temperatures are compatible with today's steam turbines, and it is non-flammable and nontoxic. The heat stored in the molten salt then flowed into thermal storage tank. Inside thermal storage tank, energy is stored as high-temperature molten salt until electricity is needed (molten salt are able to store energy for a week). From the storage, high temperature molten salt is flowed into heat exchanger act as steam generator to meet the water from water storage tank. The water will absorb heat from molten salt and converted into steam. Hot molten salt generates high quality superheated steam to drive a standard steam turbine. The remaining cooled molten salt will transported into cooled molten salt storage tank and pumped into the tower receiver. The illustration of these process could be seen on Figure 2.20 below.

Figure 4.20. Concentrated Solar Thermal Energy Plant2.2.4. Process Selection Table 4.2. Comparison of the Alternative Processes

Alternative Technology

Advantages

Disadvantages

Key Process

Equipment Concentated Solar Photocoltaic Power Plant Despite the energy lost during the concentrating process, CPV can achieve the highest efficiency among all kinds of solar technologies (40%). Although the energy consumption by a tracking system is minimal, the moving parts of the tracking system make it less reliable and increases both manufacturing and maintenance costs. In the refractive system, light from the sun is focused using a Fresnel lens (5) onto a PV cell (4) that would usually be mounted onto a small printed circuit board (PCB) which acts as heatsink. PV cells, receivers, modul, tracker, control system, inverter

CPV systems are often much less expensive to produce, because of the reduced use of semi-conductor material compared with flat-plate silicon. Even a small cloud may drop the production to zero. Unlike concentrated solar power, the storage system that can mitigate this problem above is expensive since it is much easier to store heat than electric energy. This kind of instability will not be preferable when connected to the grid. It uses solar trackers and sometimes a cooling system to further increase their efficiency

Consistent daily energy production by tracking the sun, generates very consistent energy production close to rated power throughout the day For HCPV, the price for the multi-junction cell can be 100 times more expensive than a silicon cell of the same size.

Table 4.3. Comparison of the Alternative Processes (Cont)

Alternative Technology

Advantages

Disadvantages

Key Process

Equipment Photovoltaic Solar Plant Ordinary maintenance costs are low, equal to 1% of the initial investment The efficiency of the simple steam cycle is generally lower than for other cycles such as the combined cycle. When the suns rays collide the PV modules, the electrons exceed the conduction gap and a DC electrical current flows through the terminals of the PV module. It happens for each PV module. Several PV modules, connected each other to increase the total peak power. PV module, inverter, medium voltage, cabin

It needs high running time of maintenance

CST Produce big amount of energy (around 168 GWh/year). unpredictability of the produced energy The reflectors concentrates the suns rays on the receiver and the heated fluid is transported to the energy conversion system. During this step a part of the fluid can be stored for a successive use. Then the remaining part is utilized to produce electrical energy. The energy conversion system is similar to a common fossil fuel plant utilizing a thermal steam Rankine cycle. linear parabolic trough-shaped mirrors, hydraulic circuit with molten salts, pumping systems, storage system

(Source: Authors Personal Data) We have to select one of the solar power energy method which depend on the biodiesel plant need. Using solar power for electricity production can benefit the environment in many ways compared to electricity generated from fossil fuels. Solar energy is clean and renewable. It doesnt emit carbon dioxide during operation. The major material of photovoltaic panel which is the most commonly used today is silicon. Silicon is abundant and environmentally safe. Besides, Electricity is high grade energy. This means it can be easily transferred into other forms like mechanical energy or heat. If we are able to generate economic and plentiful electricity energy, together with the easy transportation electricity energy transmission, the electric power will increase it shares in demand sectors dramatically. The table below shows the comparison between Concentrated Solar Power (CSP) , Photovoltaic (PV), and Concentrated Photovoltaic (CPV) which are the common form of solar technologies. Table 4.4. Brief Comparison of Steam Turbine, Gas Turbine, and Combined Cycle

Parameter

CSP

CPV

PV Energy Production ~ 120 GWh/y ~ 90 GWh/y ~ 75 GWh/y Annual Solar Electricity conversion efficiency 1619% 1922% (2435% peak) 1517% Levelized Cost of Electricity ($) 0.38 0.28 0.12 Land Area Occupied ~ 165 Ha ~200 Ha ~ 120 Ha

(Source: Authors Personal Data) Based on the explanation above, we can make the parameter assessment for syngas production process selection. To determine which process that we should use as the sweetening process, we use analytic hierarchy process (AHP). The Analytic Hierarchy Process (AHP) is a theory of measurement through pairwise comparisons and relies on the judgements of experts to derive priority scales. It is these scales that measure intangibles in relative terms. The comparisons are made using a scale of absolute judgements that represents, how much more, one element dominates another with respect to a given attribute. In the analytical process, first we define which parameters is prioritize in aspect of other parameters. The list are as follow: Table 4.5. Parameter for Judging in AHP

Criteria

Energy Production

Cost

Conversion

Area Energy Production 1 4 3 7 Cost 1/4 1 1/3 3 Conversion 1/3 3 1 5 Area 1/7 1/3 1/5 1

After that we, define the each method score based on the literature and the researched data. The scores are: Table 4.6. Scoring Based on Energy Production Parameter

Energy Production

CPV

CSP

PV CPV

1/4 4 CSP 4

9 PV 1/4 1/9

Table 4.7. Scoring Based on the Efficiency Parameter

Efficiency

CPV

CSP

PV CPV

1 3 1/5 CSP 1/3

1 1/7 PV 5 7

1

Table 4.8. Scoring Based on the Cost Parameter

Cost

CPV

CSP

PV CPV

1 5 9 CSP 1/5

1 4 PV 1/9 1/4

1

Table 4.9. Scoring Based on the Area Needed Parameter

Area

CPV

CSP

PV CPV

1 1/3 5 CSP 3

1 9 PV 2 1 2/5

1

After we define the value of each method for each parameters, we use the average weighted score for each parameter, the result is shown in the table below. Table 4.10. Scoring Table for the Cryogenic Distillation Technology

Leader

Criterion

Criterion Weight

Leader's weight

Weighted Score CPV Energy Production 0,547569239 0,217165613 0,118913209 Cost 0,126555284 0,188394097 0,023842268 Conversion 0,269949922 0,742866622 0,200536787 Area 0,055925554 0,229604755 0,012840773 Sum

0,356133038 CSP Energy Production 0,547569239 0,717065035 0,392642755 Cost 0,126555284 0,080961232 0,010246072 Conversion 0,269949922 0,193881633 0,052338332 Area 0,055925554 0,246643105 0,013793652 Sum

0,469020811 PV Energy Production 0,547569239 0,065769352 0,036013274 Cost 0,126555284 0,730644671 0,092466944 Conversion 0,269949922 0,063251744 0,017074803 Area 0,055925554 0,52375214 0,029291129 Sum

0,174846151

(Source: Authors Personal Data) Based on the Table 2.3, we can conclude that concenrated soalr power is the best one of the alternative process of natural gas power. The conclusion is based on the reason which we will explain here. a. Energy Production

The CPV system produces approximately 20% more energy than a fixed PV filed, on yearly basis with the same nominal installed power related to their tracker system that can move the panel towards the sunlight direction. That is the the reason we give the score 4 to the CPV and 3 to the PV, as they are producing lower energy amount compared to CSP. The biggest energy emitted from concentrated solar power due to the fact that CSP has the storage system constituted by the hot tank, which allows to produce the same amount of energy also when the radiation is low or inexistent.

b. Annual Solar Electricity Conversion Energy

As for CSP, the efficiency of the concentrated solar power systems varies a lot due to their complexity. Heat engine technology very mature and its efficiency is determined by working temperatures; so, the efficiency of a CSP system is based on the chosen structure and the gain in efficiency may not compensate for the cost and complication of the cycle which makes us decided to give 4 out of 5 for the score . In the other hand, if crystalline silicon PV modules are used (efficiency of crystalline silicon PV modules is better than the efficiency of thin film PV modules; typical values are respectively in the range of 14-16% and 10-12% that worthed score of 3 which is the least position. For CPV, it has the highest efficiency due to the mirror that concentrate the sunlight irradiaion to the receiver and also owes to the photovoltaic system that directly convert sun power to the electricity which worthed 5 in the scoring. c. Cost

Total available irradiance has a strong impact of the economics of all solar electricity generation, but particularly for concentrating solar where fixed costs and operation and maintenance is less scalable with the size of the system versus traditional PV. Second, the reliance of most CSP systems on tracking systems and the incident angle of light at different latitudes has a fi rst order effect on the LCOE. Depending on location, DNI can range from 60 to 80 percent of the total available light that is available to flatplate PV, and maximizing its capture is what requires the use of complex and precise tracking systems for most CSP technologies. From those factors above, CSP produces highest cost among other alternative, so that we give it score of 3, while CPV is the most economic alternative followed by PV. d. Land Area Occupied

The corresponding ground area typically required for the same PV field, amounts approx. to 2.2 2.5 Ha/MWp if thin film PV modules are used, while amounts approx. to 1.7 2.1 Ha/MWp if crystalline silicon PV modules are used (efficiency of crystalline silicon PV modules is better than the efficiency of thin film PV modules; typical values are respectively in the range of 14 16% and 1012%). The estimated ground area needed to build a 50MWp UtilityScale PV plant amounts to approx. 120140Ha, for fixed PV field constituted by thin film PV arrays, and to 90110Ha for fixed PV field constituted by crystalline silicon PV arrays. In case of a tracker PV field, the required ground area amounts approx. to 4 4.5 Ha/MWp , if thin film PV module are used, while amounts approx. to 3 3.5 Ha/MWp if crystalline silicon PV modules are used. Even if these different technologies and arrangements are nowadays competing with no clear winners, it can be observed that, in terms of land impact, fixed PV field requires about half of the area necessary for a Tracker PV system and as highlighted above the selection of PV modules may play an important role in determining the area required by the plant. The CSP plants land occupation depends by the total installed collector surface and also by the space between each solar collector assembly required to minimize shadows and also to allow the maintenance of the big curved reflecting mirrors. Additional surface is required for the power block and heat storage, both usually located in the middle of the plant area and with an occupation much smaller respect to the solar field. Therefore the estimated area required for a 50MW CSP plant hypothetically localized in southern Italy and based on Parabolic Through technology, amounts totally to approx. 160170 Ha. 2.1.4. Hierarchy of Decision To determining the input and output structure of flow sheet, we should consider some important things to synthesis the best process. a. Characterization of heat transfer media and storage fluids

The use of molten salt as a HTF and storage system is yielding excellent results, as provided by Gemasolar plant system based only on molten salts. The big call of TES using molten salts is to improve their capacity for storage during more than 15 hours according to different weather conditions along the. Molten salts provides numerous advantages when compared to other storage and HTF concerning specially their costs and the fact that a residual salt provided by the mining sector can be employed, which can be reused in thermo electrical solar plants to fill a storage tank and/or as a heat transfer fluid. For parabolic troughs collectors, an emergent additional option is the use of compressed gas as the heat transfer fluid and molten salt for storage. However, this option is at a very early stage of development and efficiency data are not yet available. b. Energy storage system

Active system is a two-tank system, in which the HTF is stored in a hot tank, allowing its use during the night or cloudy days. The other tank is cold, and the cooled HTF is pumped for being heated in continuous cycles (Herrmann U., et al, 2004). In Figure 2.12 is presented the system of Solar Tres project with a central tower receiver located near Seville, Spain, which was built during 2008 using a molten nitrate salts (NaNO3 and KNO3) storage two-tank system (Plataforma Solar de Almera, 2008-2009). The main advantages of a two-tank system are the fact of storing the materials separately, theres a low risk investment, the possibility to raise the solar field output temperature to 500 C and also to increase Rankine cycle efficiency of the power block steam turbine. Here is the explanation about the concentrated solar power which we are selected in the plant design, which illustration could be seen on Figure 2.21 below.

Figure 4.21. Concentrated Solar Plant In the design of concentrated solar power, the early decision to direct all hot salt from the receiver to the hot salt tank and to only operate the turbine from steam generated using salt from storage (Fig. sekian) made the collection and the dispatch of energy completely independent of each other. If there was hot salt and demand, the turbine could be operated; if there was warm salt and sunlight, the receiver could be operated, making the collected energy fully dispatchable. The low pressure of the salt compared to steam allowed much thinner walled receiver tubes to be used at Solar Two compared to Solar One. This reduced thermal stress, and along with the much better heat transfer characteristics of the salt, allowed a much higher receiver allowable fl ux density, up to 1 MW/m2 (and in future designs up to 1.5 MW/m2). Combined with a multilevel vertical aim strategy, this allows use of a much smaller receiver than used in Solar One. Because the receiver is drained every night to avoid freezing of the salt (freezing point 220C), it must be preheated each morning prior to filling, to avoid tube blockages the heliostat fi eld is used for this purpose. Only about 10% of the heliostats were used to avoid overheating of the empty tubes, and these heliostats must be selected primarily from the sunrise side of the field (where the cosine efficiency is very low) to provide a uniform heating. A special processor, which sequentially identifi es the heliostat contributing most to any computed hot spot and removes it from track, was found to be quite satisfactory for this purpose (Vant-Hull et al., 1996). Due to the high velocity of salt fl ow required to achieve the high heat transfer, the salt fl ow is multi-pass. Salt enters on the (high fl ux density) polar side, fl ows in serpentine fashion to the east and west, crosses over to balance the diurnal difference between the power delivered by the east and west fi elds, and exits from the equatorial-side panels. Here, the lower fl ux density accommodates the lower heat transfer coeffi cient of the hot salt and its propensity, at the 565C outlet temperature, to initiate corrosion in contact with the hot tube (Bradshaw, 1987; Smith, 1992). In fact, it was found to be cost effective to move some heliostats from the high-performance north fi eld to the lower-performance south fi eld. This reduced the total power on the limiting northern panels, and the resulting lower power level and fl ux density there allowed use of a shorter and lower cost receiver while remaining within the fl ux density limitation. The 565C salt in the downcomer was depressurized by fl ow restrictors and deposited in the hot salt tank at atmospheric pressure. Upon demand, hot salt was pumped through a preheater-boiler-superheater heat exchanger train, and the resulting superheated steam was directed into the same 10 MWe turbine used for Solar One. Several easily-preventable failures reduced the operating time for Solar Two. The prefabricated heat trace tape at the top end of the salt riser was found by the installers to be too long (due to use of too large a pitch while winding), so was double wound at the top to use the whole length and avoid fi eld installation of new connectors. Consequently, the top of the riser pipe became overheated and began to oxidize to the extent that, after a time, rust particles broke off and eventually caused a number of receiver tube failures due to blockage. In addition, a portion of the riser pipe had to be replaced. Better quality control during construction or an appropriate fi lter would have prevented this costly exercise. After a time, the steam generator failed. It turned out that it was designed using a common utility steam generator code. Inadequate salt circulation in a localized area resulted in excessive stress during each thermal cycle, and failure resulted after 500 cycles or so. It should be noted that 500 thermal cycles would actually represent a very long life for a utility steam generator under normal operating conditions, highlighting the challenges of using existing commercial solutions in CSP systems. It had to be removed, redesigned, and rebuilt. After two years of test and three years of grid tied operation, the receiver panels developed considerable warpage. This was initially due to inadequate allowance for thermal expansion in the original design, which assumed normal operating conditions for the panels. During off-design conditions, the entire length of the panels could be at the maximum temperature and so experience constraint and warpage. Once this constraint was remedied, residual fl ux gradients caused signifi cant additional warpage by the time operation was terminated. Several peripheral problems such as this depleted the operating budget to the extent that, shortly after the pre-designated test plan had been completed, Solar Two was shut down (in 1999) prior to signifi cant commercial operation. Thus, much of the operating experience so useful in establishing the bankability of the molten salt central receiver concept did not eventuate.

Figure 4.22. Block Flow Diagram Concentrated Solar Power (Source: Authors Personal Data) CHAPTER III MASS AND ENERGY BALANCE BIODIESEL RAW MATERIAL 4503.842022 All in kg unit Engine Driven Screw Press

No

Component

In

Out

Stream 1

Stream 2

Stream 3 1 JCO 1801.536809 1621.383128 180.1536809 2 Seeds Pulp 2702.305213 270.2305213 2432.074692 TOTAL 4503.842022 1891.613649 2612.228373

4503.842022 Assume the entering feeds were oil part and cake (seeds pulp) part, we obtain 90% purity of oil, this oil contain 10% seeds pulp residu Filter

No

Component

In

Out

Stream 2

Stream 4

Stream 5 1 JCO 1621.383128 0 1621.383128 2 Seeds Pulp 270.2305213 270.2305213 0 TOTAL 1891.613649 270.2305213 1621.383128

1891.613649 Mixer for Degumming

No

Component

In

Out

Stream 5

Stream 6

Stream 7 1 JCO 1605.169297 0 1605.169297 2 Phosporic Acid 0 3.242766256 0 3 Water 0 29.1848963 29.1848963 4 Phospolipid 16.21383128 0 1.297106502 5 Glycerol 0 0 18.15949103 TOTAL 1621.383128 32.42766256 1653.810791

1653.810791

Sulfuric acid 0.2% wt, water 1.8% wt JCO. Assume phosphat content in JCO = 1%, its reducted 92%

Centrifuge

No

Component

In

Out

Stream 7

Stream 8

Stream 9 1 JCO 1605.169297 160.5169297 1444.652367 2 Glycerol 18.15949103 18.15949103 0 3 Water 29.1848963 29.1848963 0 4 Residual Gum 1.297106502 0 1.297106502 TOTAL 1653.810791 207.861317 1445.949474

1653.810791 Mixer for Esterification

No

Component

In

Out

Stream 10

Stream 11

Stream 12 1 Methanol 0 346.6300188 346.6300188 2 HCl 14.44652367 0 14.44652367 TOTAL 14.44652367 346.6300188 361.0765425

361.0765425

Mol methanol : mol JCO = 6:1 Esterification Reactor

No

Component

In

Out

Stream 9

Stream 12

Stream 13 1 FFA 173.3582841 0 1.19617216 2 Metil Ester 0 0 172.1621119 3 Trigliserida 1271.294083 0 1271.294083 4 Residual Gum 1.297106502 0 1.297106502 5 Water 0 0 10.39890056 6 Methanol 0 346.6300188 336.2311182 TOTAL 1445.949474 346.6300188 1792.579492

1792.579492

Assume 3% methanol react and generate water Distilation Column I

No

Component

In

Out

Stream 13

Stream 14

Stream 15 1 FFA 1.19617216 0 1.19617216 2 Metil Ester 172.1621119 0 172.1621119 3 Trigliserida 1271.294083 0 1271.294083 4 Residual Gum 1.297106502 0 1.297106502 5 Water 10.39890056 10.38850166 0.010398901

6 Methanol 336.2311182 335.8948871 0.336231118 TOTAL 1792.579492 346.2833888 1446.296104

1792.579492 1% water and methanol is obtained in bottom product Mixer for Transesterification

No

Component

In

Out

Stream 16

Stream 17

Stream 18 1 Methanol 0 280.0751484 280.0751484 2 KOH 12.71294083 0 12.71294083 TOTAL 12.71294083 280.0751484 292.7880893

292.7880893

!% of KOH as catalyst Transesterification Reactor

No

Component

In

Out

Stream 15

Stream 18

Stream 19 1 FFA 1.19617216 0 0 2 Metil Ester 172.1621119 0 1414.141309 3 Trigliserida 1271.294083 0 5.085176332 4 Residual Gum 1.297106502 0 1.297106502 5 Water 0.010398901 0 0.010398901 6 Methanol 0.336231118 280.0751484 277.6106281 7 Soap 0 0 2.800751484 8 Glycerol 0 0 25.42588166 TOTAL 1446.296104 280.0751484 1726.371252

1726.371252

Standard triglyceride content excess 0.4% 1 % Soap is generated from methanol Glycerol 2%

Distilation Column II

No

Component

In

Out

Stream 19

Stream 20

Stream 21 1 Metil Ester 1414.141309 0 1414.141309 2 Trigliserida 5.085176332 0 5.085176332 3 Residual Gum 1.297106502 0 1.297106502 4 Water 0.010398901 0.010294912 0.000103989 5 Methanol 277.6106281 274.8345218 2.776106281

6 Soap 2.800751484 0 2.800751484 7 Glycerol 25.42588166 0 25.42588166 TOTAL 1726.371252 274.8448167 1451.526435

1726.371252 Dekantation + Neutralization Unit

No

Component

In

Out

Stream 21

Stream 22

Stream 23 1 Metil Ester 1414.141309 14.14141309 1399.999896 2 Trigliserida 5.085176332 5.085176332 0 3 Residual Gum 1.297106502 1.297106502 0 4 Water 0.000103989 0 0.000103989 5 Methanol 2.776106281 2.776106281 0 6 Soap 2.800751484 2.800751484 0 7 Glycerol 25.42588166 25.42588166 0 TOTAL 1451.526435 51.52643535 1400

1451.526435 Dehydrated Unit

No

Component

In

Out

Stream 23

Stream 24

Stream 25 1 Metil Ester 1399.999896 0 1399.999896 2 Water 0.000103989 0.000103989 0 TOTAL 1400 0.000103989 1399.999896

1400 PRODUCT 1400

3.2 Energy Balance All in KJ Esterification Reactor

No

Component

In

Out

Stream 9

Stream 12

Stream 13 1 FFA 527.811 0 131.95275 2 Metil Ester 0 0 183.144 3 Trigliserida 5148.82 0 5148.82 4 Residual Gum 0.0196 0 0.0196 5 Water 146.37 0 146.37

6 Methanol 0 12.051 12.051 7 Hydrochloric Acid 0 53.02 53.02 TOTAL 5823.0206 65.071 5675.37735

5888.0916

Heater

No

Component

In

Out

Stream 13

Stream 14 1 FFA 131.95275 165.9965595 2 Metil Ester 183.144 227.09856 3 Trigliserida 5148.82 8072.834878 4 Residual Gum 0.0196 0.0196 5 Water 146.37 187.265778 6 Methanol 12.051 12.53834244 TOTAL 5622.35735 8665.753718

14288.11107

Distilation Column

No

Component

In

Out

Stream 13

Stream 14

Stream 13

Stream 14 1 FFA 7961 2952.71 0 10913.71 2 Metil Ester 4375.24 2969.64 0 7344.88 3 Trigliserida 2933.06 228.22 0 3161.28 4 Residual Gum 425.85 0.933 0 426.783 5 Water 1333.72 881.129 0.473 2214.376 6 Methanol 3494.43 161.47 3449.24 206.66 Subtotal 20523.3 7194.102 3449.713 24267.689 Cooling Water 3252.12 Total 27717.402 27717.402 Condensor I

No

Component

In

Out

Stream 10

Stream 11 1 Methanol 97579.3 83866.65 2 Water 67.251 26.047 Total 97646.551 83892.697 Transesterification Reactor

No

Component

In

Out

Stream 15

Stream 18

Stream 19

1 FFA 32.928 0 0 2 Metil Ester 228.89 0 228.89 3 Trigliserida 5177.126 0 5177.126 4 Residual Gum 0.0195 0 0.0195 5 Water 1376.26 67.53 1443.79 6 Methanol 1.193 14287.58 14288.773 7 Soap 0 0 0 8 Glycerol 0 0 0 9 KOH 0 4.622 4.622 TOTAL 6816.4165 14355.11 21143.2205

21143.2205

Mixer

No

Component

In

Out

Stream 21

Stream 22

Stream 23 1 Metil Ester 3072.96 0 3072.96 2 Trigliserida 1484.97 0 1484.97 3 Water 26.34 0 26.34 4 Methanol 0.22 0 0.22 5 Soap 8.03 39810.48 39818.51 6 Glycerol 1484.97 0 1484.97 TOTAL 6077.49 39810.48 45887.97

45887.97

SOLAR SYSTEM In Out Require H101 Cold molten -2103800000 Hot Molten -1836700000 267100000

-2103800000 -1836700000 -267100000

Table 3. 26 Energy balance of H-101 Table 3. 26 Energy balance of E-101 E101 Hot Molten Salt -918370000 Molten Salt -1064400000

Steam -115390000 HP Steam -1007800000

-1033760000 -2072200000 1038440000

Table 3. 26 Energy balance of E-102 E102 Hot molten steam -918370000 Steam -992790000

Steam -1045000000 Molten salt -970520000

-1963370000 -1963310000 -60000

Table 3. 26 Energy balance of E-103 E103 Molten salt -2057200000 Molten salt -2159900000

Water -1256600000 Water -1153900000

-3313800000 -3313800000 0

Table 3. 26 Energy balance of K-101 K101 HP steam -1007800000 Steam -1045000000 -1007800000 -1045000000 37200000 Table 3. 26 Energy balance of K-102 K102 Steam -970520000 Steam -995020000

-970520000 -995020000 24500000

Table 3. 26 Energy balance of H-101 E-104 Steam -1256600000 Water -1256600000

-1256600000 1256600000 -2513200000

Table 3. 26 Energy balance of overall solar plant Comnponent In Out Require H101 Cold molten -2103800000 Hot Molten -1836700000 267100000

-2103800000 -1836700000 -267100000 E101 Hot Molten Salt -918370000 Molten Salt -1064400000

Steam -115390000 HP Steam -1007800000

-1033760000 -2072200000 1038440000 E102 Hot molten steam -918370000 Steam -992790000

Steam -1045000000 Molten salt -970520000

-1963370000 -1963310000 -60000 E103 Molten salt -2057200000 Molten salt -2159900000

Water -1256600000 Water -1153900000

-3313800000 -3313800000 0 K101 HP steam -1007800000 Steam -1045000000

-1007800000 -1045000000 37200000 K102 Steam -970520000 Steam -995020000

-970520000 -995020000 24500000

E-104 Steam -1256600000 Water -1256600000

-1256600000 1256600000 -2513200000

5. CHAPTER 4 PROCESS CONCLUSION As per what we have explained in the above, there are several things that we could conclude, they are: - Biodiesel is a kind of biofuel, which holds a good prospect as an renewable and sustainable alternative energy. - Off-grid solar system is one from many application that mi