A PLANT DESIGN OF BIODIESEL ADDITIVE PRODUCTION FROM TERT-BUTYLHYDROQUINONE AND SURFACTANT GLYCEROL
MONOSTEARATE
By
Valenci Roselina Himawan 11604009
BACHELOR’S DEGREE in
CHEMICAL ENGINEERING - SUSTAINABLE ENERGY AND ENVIRONMENT FACULTY OF LIFE SCIENCES AND TECHNOLOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No.15 Alam Sutera Tangerang, Banten 15143 - Indonesia
June 2020
Revision after the Thesis Defense on 08 July 2020
STATEMENT BY THE AUTHOR
I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Valenci Roselina Himawan
_____________________________________________
Student
15-06-2020 Date
Approved by:
Silvya Yusri, S. Si., M. T.
_____________________________________________
Thesis Advisor
15-06-2020 Date
(OPTIONAL)
Dr. Hery Sutanto, M.Si.
_____________________________________________
Thesis Co-Advisor
15-06-2020 Date
Dr. Dipl.-Ing. Samuel P. Kusumocahyo
_____________________________________________
Dean
15-06-2020 Date
ABSTRACT
A PLANT DESIGN OF BIODIESEL ADDITIVE PRODUCTION FROM TERT- BUTYLHYDROQUINONE AND SURFACTANT GLYCEROL MONOSTEARATE
By
Valenci Roselina Himawan Silvya Yusri, S. Si., M. T., Advisor Dr. Hery Sutanto, M.Si., Co-Advisor
SWISS GERMAN UNIVERSITY
Biodiesel is a type of renewable fuel which is biodegradable and does not emit hazardous material. However, biodiesel is prone to oxidation and could cause problem in the engine. Addition of antioxidant tert-butylhydroquinone (TBHQ), as one of the best antioxidants, is able to prevent oxidation. Nevertheless, antioxidant is also partially soluble in biodiesel as it is partially polar while biodiesel is very nonpolar and could cause undesired sedimentation. To overcome this insolubility problem, addition of antioxidant and surfactant combination is used in the previous study. Antioxidant TBHQ and surfactant glycerol monostearate (GMS) were proven as the best combination. This combination showed a satisfying result in terms of induction period, its performance almost equals Baynox, the commercial antioxidant. This combination has the potential to be commercially manufactured. However, since it is a new research, no upscaling design have been made. Therefore, in this thesis the design of the industrial process of this new additive is made. The designed plant capacity is 480 tons/year. The economic feasibility shows that this project is profitable.
Keywords: plant design, biodiesel additive, antioxidant, TBHQ, surfactant, GMS.
© Copyright 2020 by Valenci Roselina Himawan
All rights reserved
DEDICATION
I dedicate this thesis for my family and my country Indonesia.
ACKNOWLEDGEMENT
Foremost, I would like to express my gratitude to God and Jesus Christ for His grace and the strength He gave, so that I can finish this thesis work. This thesis “A Plant Design of Biodiesel Additive Production from Tert-Butylhydroquinone and Surfactant Glycerol Monostearate” is written for achieving bachelor’s degree in Swiss German University. This work cannot be finished without support and guidance from those whose names are mentioned below:
1. Deepest thanks to Silvya Yusri, S. Si., M. T and Dr. Hery Sutanto, M.Si as my advisor and co-advisor, who helped me and guided me finishing my thesis work.
2. My family, Mami Naftali Christina and Papi Deni Indramawan, my brothers, and my whole big family who have supported me and encouraged me in completing this thesis work.
3. All my Sustainable Energy and Environment 2016 friends who have shared their journey together with me.
4. All Swiss German University lecturers for the knowledge they taught me.
5. Deepest gratitude to Stefani Christanti, S. Ak and Steven Feriano Himawan who helped me a lot in finishing this thesis.
6. My friends Evelyn, Evita, Fani, Ivana, Tirza, Kak Azi, Kak Vinna, Aisyah, and many more for always cheering me during my thesis work.
7. UD. Mayar Machine Supplier and Alumni of Civil Engineering Atmajaya Yogyakarta 1998 for the consultation and information regarding the technical machine issue.
8. Special thanks to BTS who encouraged me through their music and arts.
TABLE OF CONTENTS
Page
STATEMENT BY THE AUTHOR ...2
ABSTRACT ...3
DEDICATION ...5
ACKNOWLEDGEMENT ...6
TABLE OF CONTENTS ...7
LIST OF FIGURES ... 11
LIST OF TABLES... 13
CHAPTER 1 - INTRODUCTION ... 15
1.1. Background ... 15
1.2. Research Problems ... 17
1.3. Research Objectives ... 17
1.4. Significance of Study ... 17
CHAPTER 2 - LITERATURE REVIEW ... 18
2.1. Energy Situation ... 18
2.1.1. World Energy ... 18
2.1.2. Indonesia ... 18
2.1.3. Renewable Energy ... 19
2.2. Biodiesel ... 19
2.2.1. Definition of Biodiesel ... 19
2.2.2. Standard Biodiesel Parameter ... 21
2.2.3. Advantages of Biodiesel ... 27
2.3. Antioxidant... 28
2.3.1. Tert-butylhydroquinone (TBHQ) ... 29
2.3.2. Insolubility of Antioxidant in Biodiesel ... 30
2.4. Surfactant ... 31
2.4.1. Formation of Micelle ... 32
2.4.2. Glycerol Monostearate... 33
2.4. Mixing ... 33
2.4.1. Ribbon Blender ... 34
2.4.2. Screw Conical Mixer ... 34
2.4.3. Tumbling Mixer ... 34
2.5. Grinding ... 35
2.5.1. Hammer Mills ... 35
2.5.2. Roller-compression Mills ... 36
2.5.3. Attrition Mills... 36
2.5.4. Tumbling Mills ... 36
2.6. Sieving ... 37
2.7. Granulation... 37
2.7.1. Slugging Method ... 38
2.7.2. Roller Compaction ... 38
CHAPTER 3 - RESEARCH METHODS ... 39
3.1. Venue and Time ... 39
3.2. Experimental Design ... 39
3.3. Experimental Procedure ... 40
3.3.1. Literature Study and Data Assessment ... 40
3.3.2. Market Research ... 40
3.3.3. Designing Process Flow Diagram (PFD) ... 41
3.3.5. Feasibility Study ... 42
CHAPTER 4 - RESULT AND DISCUSSION ... 43
4.1. Market Research Data... 43
4.2. Formulation of the Product ... 45
4.3. Products Need in Indonesia... 46
4.4. Location and Capacity of the Plant ... 46
4.5. Process Flow Diagram ... 47
4.6. Process Description ... 48
4.6.1. Milling and Sieving ... 48
4.6.2. Mixing... 50
4.6.3. Granulation ... 52
4.6.4. Packing ... 53
4.7. Material Balance... 54
4.8. Energy Balance ... 63
4.9. Utilities... 67
4.9.1. Estimated Electricity Need ... 67
4.9.2. Water Consumption ... 71
4.10. Business Concept ... 71
4.10.1. Product Description ... 71
4.10.2. Organizational Structure ... 72
4.10.3. Employment Qualification ... 78
4.10.4. Payroll System ... 80
4.10.5. Working Hour ... 82
4.10.6. Product Competitors ... 82
4.10.7. Targeted Market ... 83
4.10.8. Marketing Plan ... 83
4.11. Feasibility Study ... 86
4.11.1. Total Capital Investment ... 87
4.11.2. Cost of Goods Manufactured (COGM) ... 88
4.11.3. Profit and Loss Report ... 88
4.11.4. Cash Flow Report ... 90
4.11.5. Breakeven Point (BEP) ... 92
4.11.6. Net Present Value and Payback Period Analysis ... 93
CHAPTER 5 - CONCLUSIONS AND RECOMMENDATIONS ... 95
5.1. Conclusions ... 95
5.2. Recommendations ... 95
GLOSSARY ... 96
REFERENCES ... 97
APPENDICES ... 107
CURRICULUM VITAE ... 111
LIST OF FIGURES
Page Figure 2.1 Mechanism of Transesterification Process. Adopted from (Manzanera et
al., 2008) ... 19
Figure 2.2 Mechanism of Esterification Process. Adopted from (Haigha et al., 2012)20 Figure 2.3 Molecular Structure of TBHQ. Adopted from (Almeida, 2015) ... 29
Figure 2.4 Surface Tension vs Surfactants Concentration. Adopted from (KRÜSS, n.d.) ... 32
Figure 2.5 Glycerol Monostearate (GMS) Molecular Structure (National Center for Biotechnology Information, 2020) ... 33
Figure 3.1 Experimental Design ... 39
Figure 3.2 Material Balances Equation... 41
Figure 3.3 Energy Balances Equation ... 41
Figure 4.1 Biodiesel Production Quota in Indonesia (PT Indeks Komoditas Indonesia, 2020) ... 43
Figure 4.2 Biodiesel Producer Distribution in Indonesia. Data adopted from (PT Indeks Komoditas Indonesia, 2020) ... 44
Figure 4.3 Comparison of TBHQ+GMS performance and Baynox in Biodiesel. Data adopted from (Hery Sutanto, 2019) ... 45
Figure 4.4 Process Flow of Diagram of Biodiesel Additive Plant ... 47
Figure 4.5 Hammer Mill Illustration. Adopted from (feedmachinery, n.d.) ... 48
Figure 4.6 Hammer Mill Equipment ... 49
Figure 4.7 Vibrating Sieve Equipment ... 49
Figure 4.8 Vacuum Conveyor ... 50
Figure 4.9 Ribbon Blender Equipment ... 51
Figure 4.10 Screw Conveyor Feeder ... 52
Figure 4.11 Dry Granulation Equipment ... 52
Figure 4.12 Detailed Stream Flow in Vibrating Sieve TBHQ, 1st Screening ... 54
Figure 4.13 Detailed Stream Flow in Hammer Mill for TBHQ ... 55
Figure 4.15 Detailed Stream Flow in Hammer Mill for GMS ... 56
Figure 4.16 Detailed Stream Flow in Vibrating Sieve for GMS ... 57
Figure 4.17 Detailed Stream Flow in Powdered TBHQ Tank ... 58
Figure 4.18 Detailed Stream Flow in Powdered GMS Tank ... 59
Figure 4.19 Detailed Stream Flow in Ribbon Blender ... 59
Figure 4.20 Detailed Stream Flow in Screw Conveyor ... 60
Figure 4.21 Detailed Stream Flow in Roller Compaction ... 61
Figure 4.22 Detailed Stream Flow in Product Storage Tank ... 62
Figure 4.23 Detailed Stream Flow in Packing Machine ... 62
Figure 4.24 Packaging Illustration of the Product ... 72
Figure 4.25 Organizational Structure ... 73
Figure 4.26 The Design of the Plant (Front View) ... 84
Figure 4.27 The Design of the Plant (Upside View) ... 84
Figure 4.28 Plant Layout First Floor ... 85
Figure 4.29 Layout of The Second Floor ... 85
Figure 4.30 Break Even Analysis Graph ... 93
LIST OF TABLES
Page Table 2.1 The American Standard of Biodiesel ASTM D6751. Adopted from (Barabas
& Todoru, 2011) ... 21
Table 2.2 The European Standard of Biodiesel EN 14214. Adopted from (Barabas & Todoru, 2011) ... 23
Table 2.3 The Indonesian Standard of Biodiesel SNI 7182 ... 25
Table 2.4 Comparison of Oxidation Parameter from ASTM, EN, and SNI ... 27
Table 2.5 Rancimat Test Result, adopted from (Hery Sutanto, 2019) ... 31
Table 4.1 Material Balance in Vibrating Screening of TBHQ... 54
Table 4.2 Material Balance in Milling of TBHQ ... 55
Table 4.3 Material Balance in Vibrating Screening of TBHQ... 56
Table 4.4 Material Balance in Milling of GMS ... 57
Table 4.5 Material Balance in Screening of GMS ... 58
Table 4.6 Material Balance in TBHQ Tank ... 58
Table 4.7 Material Balance in GMS Tank ... 59
Table 4.8 Material Balance in Ribbon Blender ... 60
Table 4.9 Material Balance in Screw Conveyor ... 60
Table 4.10 Material Balance in Dry Granulator - Roller Compaction ... 61
Table 4.11 Material Balance in Additive Storage Tank ... 62
Table 4.12 Material Balance in Packing System ... 62
Table 4.13 The Overall Material Balance ... 63
Table 4.14 Energy Balance of Cooling in Hammer Mill for TBHQ ... 65
Table 4.15 Energy Balance of Cooling in Hammer Mill for GMS ... 66
Table 4.16 Total Electricity Consumption for Lighting ... 68
Table 4.17 Electricity Consumption for Production Process ... 69
Table 4.18 Prediction of Air Conditioner Power Capacity over Area of Room ... 69
Table 4.19 Total Electricity Consumed for Air Conditioning ... 70
Table 4.20 Education Requirement for each Position ... 78
Table 4.22 Fixed Capital Investment ... 87
Table 4.23 Manufacturing Cost ... 88
Table 4.24 Profit and Loss Report on the First Year ... 89
Table 4.25 Profit and Loss Report of the Third Year ... 90
Table 4.26 Cash Flow Report on Year 0 ... 91
Table 4.27 Cash Flow Report on the First Year ... 91
Table 4.28 Breakeven Sales Analysis ... 92
Table 4.29 Net Present Value Analysis ... 94
