Lecture at Manila

THEME

1. Innovations in Extraction / Processing

2. Quality & Characteristics of FAME using Jatropha Oil

3. Factors to consider in Managing Large Scale Plantations

Innovations in Extraction / Processing
OIL EXTRACTION

1. Dehulling

2. Seed Preparation

3. Oil Milling

4. Solvent Extraction

5. Solvent Removal

Dehulling

1. Fruits are Dried, Cleaned of mud, Stones Removed.

2. Seeds removed from Dry Fruit cover.

3. Hulls removed if oil used for soap.

4. Hulls not removed if used as fuel.

Seed Preparation

1. Cracked in Cracking Mill Rolls.

2. Flaked in Hydraulic Flakers.

3. Transported to the Extraction Plant.

Solvent Extraction

1. Extractor with stainless steel Belt and Hexane Spay System.

2. Regulated speed Belt to change Capacity and Oil yield.

3. Cake filtered through special wedge wire filters.

Solvent Removal

1. Distillation and Recovery of Hexane by Evaporation.

2. Series of Distillation / Condensation Units.

3. Final operation under vacuum.

4. Hexane Recycled for Oil Extraction.

5. Vent vapors absorbed in oil to recover Hexane Vapors.

Flash Solvent Removal

1. Solvent in Cake removed by flashing.

2. Cake passed through flash tubes and cyclone.

3. Cake and Hexane recovered.

REFINING

1. Degumming

2. Neutralization

3. Bleaching

Phosphotites in the Oil are hydrated with water and removed by separating in the Centrifugal Separators.

It is the treated with Phosphoric Acid and Caustic Soda to remove Free Fatty Acids. The neutralized oil is then washed. Neutralized oil is then dried.

BLEACHUNG

1. Done if Jatropha Oil used for soap Manufacture.

2. Bleaching earth used to remove impurities.

3. Oil filtered through pressure leaf filter.

Quality & Characteristics of FAME using Jatropha Oil

1. Density g/ml (30°C)

2. Combustion point (°C)

3. Kinematic viscosity constant cSt (30°C)

4. Calorific potential (MJ/kg)

5. Cetane number

6. Ester content (%)

7. Sulphur content (%)

8. Carbon residue (%)

Density g/ml (30°C)

1. Jatropha Curcas Methyl Ester = 0.88

2. Diesel = 0.85

3. Norms for ester fuel = >0.8

4. Density should be comparable to Diesel

Combustion point (°C)

1. Jatropha Curcas Methyl Ester = 192

2. Diesel = 55

3. Norms for ester fuel > 55

4. Higher the combustion point, it is safer to handle and transport

Kinetic viscosity constant cSt (30°C)

1. Jatropha Curcas Methyl Ester = 4.84

2. Diesel = 2 to 8

3. Norms for ester fuel ~ 5

4. Most important property for flow of fuel through fuel pump and pipes

Calorific potential (MJ/kg)

1. Jatropha Curcas Methyl Ester = 41

2. Diesel = 45

3. Norms for ester fuel : Not Defined

4. It is 87 to 90% of Diesel due to presence of 2 oxygen molecules.

Cetane number

1. Jatropha Curcas Methyl Ester = 52

2. Diesel = 47.5

3. Norms for ester fuel > 48

4. Combustion quality of fuel in a diesel engine.

Ester content (%)

1. Jatropha Curcas Methyl Ester > 99

2. Diesel = 0

3. Norms for ester fuel > 99

4. Shows conversion of oil to ester

Sulphur content (%)

1. Jatropha Curcas Methyl Ester = 0

2. Diesel < 0.5

3. Norms for ester fuel < 0.55

4. Should be as low as possible to reduce pollution

Carbon residue (%)

1. Jatropha Curcas Methyl Ester = 0.024

2. Diesel <0.35

3. Norms for ester fuel <0.1

4. Reduces problems of chocking

Factors to consider in Managing Large Scale Plantations

1. Size of Manageable Plantation

2. 10,000 Hectares (100 square Km)

3. 5,000 Hectares (50 Square Km)

4. 2,500 Hectares (25 square Km)

5. 1,000 Hectares (10 square Km)

6. Divide large plantations into segments of 2,500 hectares.

2,500 Hectare Plantation

1. Boundary of Area

2. Contours of Area

3. Water Bodies

4. Clearing the area

5. Internal Roads

6. Housing, food, water, electricity for labour

7. Transport of labour and goods

8. Nursery and Plantation

9. Pruning and Maintenance

10. Harvesting

Boundary of Area
Plot may be

1. Square – easier to manage

2. Rectangular – longer roads

3. Irregular – difficult to map

4. Sloping – better for water drainage and irrigation

5. Rocky Patches – useful for housing / storage sheds

Contours of Area

1. Mapping to be done

2. Some leveling required

3. Make water channels

4. Create localized water bodies

5. Difficult to use machines on sloping lands

Water Bodies

1. Use water from existing rivers

2. Quality of water

3. Create ponds / percolation tanks

4. Sink Tube wells

5. Sprinkling network

6. Pumps and pumping cost

Clearing the area

1. Leave large trees

2. Cut small bushes above ground

3. Mulch cut bushes into soil

4. Mix farm yard manure (FYM)

5. Level the ground

6. Do not burn the bushes

7. Do not disturb organic system

Internal Roads

1. Use existing roads

2. Main road every Km

3. Create feeder roads every 200 meters

4. Should be suitable for tractors, trucks

5. Should not be steep

6. Support sheds along roads

7. Water channels should be away from road

Housing, food, water, electricity

1. Housing close to main road

2. Relocatable houses

3. Preferably on sloping or rocky land

4. Water through tube wells

5. Disposal of effluent

6. Food supply through mobile kitchens

7. Mobile electric supply units

Transport of labour and goods

1. Preferably in trucks

2. Labour from camps to farm

3. Product from farm to storage

4. Distributed storage bins for seeds

5. Central collection system

6. Managers, supervisors for every 2,500 hectares

Nursery

1. One for every 2,500 hectares

2. Nursery size will be 25 hectares

3. Jatropha seeds required will be 15 tons

4. Organic fertilizer required will be 15 tons

5. Water required 25,000 cubic meters per month for 3 months

Nursery Manpower
Man hours per hectare of Plantation

1. Mixing of Manure / Seeds Sowing : 50

2. Mixing of Fertilizer / Application : 10

3. Nursery Raising : 12

4. Transport of plants : 3

5. Total : (75)

Plantation
2 X 2 meters for manual plantation
3 X 2 meters for mechanized plantation
Man hours per hectare of Plantation

1. Digging of Pits : 250

2. Planting : 200

3. Misc : 10

4. Total : (460)
   Digging time can be reduced by using Post Hole Diggers attached to tractors