PRELIMINARY DESIGN OF BIODIESEL PLANT FROM WASTE VEGETABLE OIL (WVO) AND METHANOL PRELIMINARY DESIGN OF BIODIESEL PLANT FROM WASTE VEGETABLE OIL (WVO) AND METHANOL WITH CAPACITY OF 15,000 TON/ YEAR.

PRELIMINARY DESIGN OF BIODIESEL PLANT FROM WASTE
VEGETABLE OIL (WVO) AND METHANOL
WITH CAPACITY OF 15,000 TON/ YEAR

By:

Salam Noureddin Aridin
D500122008

Supervisor:
1. Rois Fatoni, ST, MSc, Ph.D
2. Ir. Nur Hidayati, MT., Ph.D

CHEMICAL ENGINEERING DEPARTMENT
FACULTY OF ENGINEERING
UNIVERSITAS MUHAMMADIYAH SURAKARTA
2016

Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
15,000 ton/year

ACKNOWLEDGEMENT

The author says thanks to Allah SWT who gives the blessings, so the
author can be able to finish the final a project “Preliminary design of Biodiesl
plant from waste vegetable oil and methanol under Ultrasound Agitations,
15,000 ton/years”.
In arranging the report, the author gets supports from several parties. Because of
that, the author wants to say thanks to:
1. Allah SWT who has given me His mercy and His blessings.
2. Father Noureddin Aridin, sister Samar Aridin, brothers (Nasser, Mohammed,
Firas, Suhail), little niece Salam, and my beloved Yudha Rahman, who
always pray and give a boost to the author in order to completing this report.
3. Mr.Rois Fatoni, ST, MSc, Ph.D as supervisor I.
4. Mrs. Ir. Nur Hidayati, MT., Ph.D as supervisor II.

The author realizes that in the preparation of plant task, there is still a
shortage. Therefore, the author expects the suggestions and criticism from
readers, so it can be used as a consideration. The author hopes that this plant
design tasks can be useful to the readers.

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Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
15,000 ton/year

PELIMINARY DESIGN OF BIODIESEL PLANT FROM
WASTE VEGETABLE OIL (WVO) AND METHANOL UNDER
ULTRASONIC AGITATION
15,000 TON/YEAR
Salam Noureddin Nassereddin Aridin

Chemical Engineering Department
Universitas Muhammadiyah Surakarta
Email: amyourcoach123010@gmail.com

ABSTRACT
Biodiesel is a fatty acid methyl or ethyl esters from vegetable oil or
animal fat and is used majorly as fuel in diesel engines vehicles, which is done by
esterification process in this research using homogeneous catalyst, the commonly
known biodiesel catalysts are homogeneous basic catalysts as Sodium hydroxide

and Potassium hydroxide. In this plant design the ultrasonic field induced an
affective emulsification and mass transfer so that the mass of ester formation
under ultrasonic mixing condition will be higher than that under stirring condition.
Emulsification is the first preparation of fat for chemical digestion by specific
enzymes. This preliminary plant design represents the study of designing a
biodiesel plant capacity of 15,000 ton/year, under Ultrasound agitation in the
reactor as the mixing method.
Economic analysis of the plant resulted a ROI (Return On Investment) of
26% before cutting the tax to be 21% after tax. POT (Pay Out Time) was
calculated to be 2.5 years before tax and 3.5 years after tax. As for BEP (Break
Even Point) 53% which means if the plant sell less than 53% there will be no
profit. SDP (Shut Down Point) value resulted as 29%, and DCF (Discounted
Cash Flow) is 9%.
After suggesting to increase the plant capacity to 50% of the original
capacity due to low profit and high BEP, According to the economic analysis, this
plant has a profit of Rp.183,460,241,614 per year, and of Rp.137,595,181,210 per
year after a 25% tax. Percent of Return On Investment (ROI) before tax 80%,
after tax 60%. Pay Out Time (POT) before tax is for 1.1 year, and after tax is for
1.5 year. Break Even Point (BEP) value is 28% and Shut Down Point (SDP) value
is 16%. Discounted Cash Flow ( DCF) is as much as 26%. According to the

previous results, this plant is considered feasible to build in Bontang.

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Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
15,000 ton/year

ABSTRAK
Biodiesel adalah asam lemak metil atau etil ester dari minyak nabati
atau lemak hewan dan digunakan majorly sebagai bahan bakar di mesin diesel
kendaraan, yang dilakukan oleh proses esterifikasi dalam penelitian ini
menggunakan katalis homogen, katalis biodiesel umum dikenal adalah katalis
dasar homogen seperti Sodium hidroksida dan Kalium hidroksida. Dalam tanaman
ini merancang bidang ultrasonik diinduksi emulsifikasi afektif dan perpindahan
massa sehingga massa pembentukan ester dalam kondisi pencampuran ultrasonik
akan lebih tinggi dari yang di bawah pengadukan condition.Emulsification adalah
thefirstpreparation dari fatforchemicaldigestion oleh specificenzymes. desain
tanaman awal ini merupakan studi merancang kapasitas pabrik biodiesel dari
15.000 ton / tahun, di bawah USG agitasi dalam reaktor sebagai metode
pencampuran.

analisis ekonomi tanaman menghasilkan ROI (Return On Investment)
dari 26% sebelum pemotongan pajak menjadi 21% setelah pajak. POT (Pay Out
Time) dihitung menjadi 2,5 tahun sebelum pajak dan 3,5 tahun setelah pajak.
Adapun BEP (Break Even Point) 53% yang berarti jika tanaman menjual kurang
dari 53% tidak akan ada keuntungan. SDP (Shut Down Point) nilai hasil 29%, dan
DCF (Discounted Cash Flow) adalah 9%.
Setelah menyarankan untuk meningkatkan kapasitas pabrik menjadi 50% dari
kapasitas aslinya karena keuntungan rendah dan BEP tinggi, Menurut analisis
ekonomi, tanaman ini memiliki keuntungan Rp.183,460,241,614 per tahun, dan
dari Rp.137,595,181,210 per tahun setelah 25 % pajak. Persen dari Return On
Investment (ROI) sebelum pajak 80%, setelah pajak 60%. Pay Out Time (POT)
sebelum pajak adalah untuk 1,1 tahun, dan setelah pajak selama 1,5 tahun. Break
Even Point (BEP) nilai adalah 28% dan Shut Down Point (SDP) nilai adalah 16%.
Discounted Cash Flow (DCF) adalah sebanyak 26%. Menurut hasil sebelumnya,
tanaman ini dianggap layak untuk membangun di Bontang.
Kata kunci: Biodiesel, USG, Bio-energi, CSTR, gliserol

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15,000 ton/year

Motto
“In great success comes great responsibility.”
(Salam Aridin)

They held themselves to ALLAH SWT ,
So ALLAH always remember them.
(Mr.Suwardi)
“The only one who can motivate you, is yourself”
(Salam Aridin)
“Nothing is impossible, as long as you believe you can do it.”
(Salam Aridin)
“What does not kill us, makes us stronger”
(Friedrich Nietzsche)

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Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
15,000 ton/year

DEDICATION
This work is dedicated for:
My beloved mom who passed away long time ago, i believe she is
in a better place and i hope she is proud of me up there .
My beloved father for always being there, supporting, advising and
loving me.
My sister and second mom, thank you for being there when nobody
was, and thank you for helping when you’re not obligated to.
My four beloved brothers, i want to say that (YOU MAKE ME
STRONGER!).
My lovely niece, thank you for bringing the joy in our lives.
Myself, for spending 4 years studying abroad and for accepting this
challenge.
My love and partner in life to be, thank you for the full support and
your great spirit through my worst times.
My classmates, thank you for understanding me and sharing your
special moments with me these four years, you’ll always be in my
mind, may Allah bless you all .

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Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
15,000 ton/year

CONTENT
Acknowledgment......................................................................................................i
Abstract....................................................................................................................ii
Motto.......................................................................................................................iii
Dedication...............................................................................................................iv
Content.....................................................................................................................v
Table of Figures.....................................................................................................vii
Figure Content.........................................................................................................ix
CHAPTER I.............................................................................................................1
INTRODUCTION....................................................................................................1
1.1.Background..................................................................................................1
1.2.Site selection for the plant............................................................................8
1.3.Literature review........................................................................................10
1.4.Use of product............................................................................................15
1.5.Physical and chemical properties of raw materials and product..............16

1.6.General process overview.........................................................................21
CHAPTER II .........................................................................................................22
PROCESS DISCRIPTION.....................................................................................22
2.1 Specification of raw material and products................................................22
2.2 Concept of process.....................................................................................24
2.3 Process flow diagram.................................................................................31
2.4 Mas and energy conservation.....................................................................34
2.5 Plant and process tool layout.....................................................................51
CHAPTER III.........................................................................................................53
PROCESS TOOLS SPECIFICATION..................................................................53
3.1 Specifications of main tools.......................................................................53

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Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
15,000 ton/year

3.2 Specifications of secondary tools...............................................................57
CHAPTER IV .......................................................................................................87
UTILITIES AND LABORATORIES....................................................................87

4.1 The supporting Process .............................................................................87
4.2 Laboratory................................................................................................116
4.3 Health and safety at work.........................................................................118
CHAPTER V........................................................................................................122
MANAGEMENT.................................................................................................122
CHAPTER VI......................................................................................................138
ECONOMIC ANALYSIS....................................................................................138
6.1 Equipments’ price approximation............................................................142
6.2 Basic Calculation.....................................................................................145
6.3 Total fixed capital investment (FCI)........................................................145
6.4 Working capital (WC).............................................................................146
6.5 Manufacturing cost (MC).........................................................................146
6.6 General expenses (GE).............................................................................147
6.7 Feasibility analysis ..................................................................................148
CHAPTER VII.....................................................................................................153
DISCUSSION AND CONCLUSION..................................................................153

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15,000 ton/year

FIGURE CONTENTS

Figure 1.1 Diagrammatic figure of global fuel production (World Ethanol and
biomass Report 2008)..............................................................................................4
Figure 1.2 World consumption of biodiesel (World Ethanol and biomass Report
2008)........................................................................................................................5
Figure 1.3 Production and export of biodiesel in Indonesia from 20062013(USDA Prodction and export in Indonesia 2006-2013)..................................7
Figure 1.4 Location of methanol plant in Bontang PT.Kaltim methanol industry
(Google maps 2015)................................................................................................8
Figure 1.5 Schematic representation of the transesterefication of triglycerides with
methanol to produce fatty acid methyl ester..........................................................10
Figure 1.6 Illustration of biodiesel processor, reactor and transducer (continious
process) (Hielscher-Ultrasound Technology 2007)...............................................12
Figure 1.7 Process flow diagram of biodiesel production......................................21

Figure 2.3.1 Qualitative process layout .................................................................32
Figure 2.3.2 Quantitative process layout (kg/h).....................................................33
Figure 2.1 Mass balance flow diagram..................................................................34
Figure 2.2 Plant layout...........................................................................................50

Figure 6.1 Chemical engineering index cost........................................................144
Figure 6.2 Feasibility analysis graph...................................................................152

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15,000 ton/year

TABLE CONTENT
Table 1.1 comparative view of minimum biodiesel mandatory program in
Indonesia, 2008-2025...............................................................................................3
Table 1.2 Data import of biodiesel in Indonesia......................................................6
Table 1.3 Capacity data of biodiesel in Indonesia 2006-2013(PT.Kreatif Energy
Indonesia, www.indobiofuel.com)...........................................................................7
Table 1.4 Fatty acid composition (wt%) in WVO and CVO.................................14
Table 1.5 Comparison between the properties of WVO and WCO.......................14
Table 1.6 Biodiesel standards DIN V 51606.........................................................20
Table 2.1 Standard enthalpy change of formation ΔH˚f of the reaction
components............................................................................................................26
Table 2.2 Standard enthalpy change of formation ΔG˚f of the reaction
components............................................................................................................27
Table 2.3 Mas conservation stream for each component.......................................35
Table 2.4 Mass balance in mixer (M-01)...............................................................35
Table 2.5 Mass balance of reactor (R-01)..............................................................36
Table 2.6 Mass balance of decanter (H-1.1)..........................................................36
Table 2.7 Mass balance of washing tank (H-2.1)...................................................37
Table 2.8 Mass balance of flash drum (D-1.1)......................................................37
Table 2.9 Mass balance of Distillation column (D-2.1).........................................38
Table 2.10 Total mass balance (overall)................................................................39
Table 2.11 Heat balance for mixer (M-01)............................................................39
Table 2.12 Heat balance for heat exchanger (E-1.1).............................................40
Table 2.13 Heat balance for heat exchanger (E-1.2).............................................40
Table 2.14 Heat balance for reactor (R-01)...........................................................40
Table 2.15 Heat balance for decanter (H-1.1)........................................................41
Table 2.16 Heat balance for heat exchanger (E-1.3)..............................................41
Table 2.17 Heat balance for washing tank (H-2.1)................................................41
Table 2.18 Heat balance for heat exchanger (E-1.4)..............................................42
Table 2.19 Heat balance for flash drum (D-1.1)....................................................42

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Preliminary design of Biodiesel plant from WVO (waste vegetables oil) and methanol.
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Table 2.20 Heat balance for cooler 1 (E-2.1).........................................................42
Table 2.21 Heat balance for cooler 2 (E-2.1).........................................................43
Table 2.22 Heat balance for collecting tank (T-1.3)..............................................43
Table 2.23 Heat balance for distillation column (D-2.1).......................................43
Table 2.24 Heat balance for cooler (E-2.3)............................................................44
Table 2.25 Heat balance overall.............................................................................44
Table 2.26 Plant land area to manufacture.............................................................48

Table 4.1 Cooling water needed...........................................................................102
Table 4.2 Water supply to steam (Saturated steam).............................................104
Table 4.3 Calculating the steam demand for heating...........................................106
Table 4.4 Power consumption for purposes process............................................110
Table 4.5 Power consumption for lighting...........................................................112

Table 5.1 The work schedule for each team........................................................130
Table 5.2 Position classification, number of employees and salaries..................133

Table 6.1 Price of equipment is done by using a price index data 1995-2020....143
Table 6.2 Total fixed capital investment .............................................................145
Table 6.3 Working capital (WC)..........................................................................146
Table 6.4 Manufacturing cost of plant.................................................................146
Table 6.5 General expenses..................................................................................147

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