“Production of Refined Rice bran Wax”

BACHELOR OF TECHNOLOGY
IN
OIL TECHNOLOGY

HARCOURT BUTLER TECHNICAL

UNIVERSITY
Name - Prashant Singh
Sachin Kumar
Class - Final Year
Branch - Oil Technology
Roll no - 200111006, 200111011
 RICE BRAN WAX ?

 Rice Bran Wax is a high melting point vegetable wax obtained

from winterization of rice bran oil.

 Rice Bran Wax primarily consists of high molecular weight

monoesters ranging from C-46 to C-66.

 Our refinement process allows the wax to retain policosanols,

phospholipids, phytosterols and squalene for superior quality.

 It is ester of saturated fatty acid and long chain alcohol.

Grading of rice bran wax
Physio-chemical properties of rice bran wax
 Purification of rice bran wax

HYRAULLIC PRESS SOLVENT EXTRACTION

HYDRAULLIC PRESS METHOD

 Hydraulic pressing of wax sludge in the pressure

range 5-50 psi using hydraulic press.

 Rice bran wax sludge consists of 28- 32 % of oil

in it.
 We use PP bags of 22 kg of quantity to separate
out the oil from the wax sludge with help of
hydraullic press.

Final oil left behind is 8-10% in the pressed wax .

SOLVENT EXTRACTION METHOD

 Extraction of de-oiled wax-sludge with non-polar solvent of the kind such as herein described in a ratio of
about 1:2 under stirring for a period of about 30 minutes at room temperature ranging from 25-35°C

 Collection of wax layer and solvent removal from the said wax layer under 15 inch vacuum to obtain the
purified wax.
 In an embodiment of the present invention, the pressure applied is in the range 5-50 psi.
 In another embodiment of the present invention, the non-polar aliphatic hydrocarbon solvent is selected
from hexane, n-hexane, and any of the C5-C8 carbon chain length aliphatic hydrocarbon solvents viz.,
petroleum ether, pentane hexane, heptane and octane..

 Purified wax is recovered by decantation followed by solvent removal.

 The purified wax we getting about 97.5% pure.

LAB ANALYSIS .

 9 kg of wax-sludge was pressed using a low pressure press at 30 psi to get 6.3 kg of partially
de-oiled wax and 2.2 kg of the oil fraction. Later, 500g of the partially de-oiled wax was
treated with 2000ml X 4 of the C6 aliphatic hydrocarbon solvent and after

30 minutes, the wax layer and the oil layer were separated at

Atomospheric pressure, desolventized under 15 inch vacuum to get

lOO g of wax of 97.5% purity and 400g of oil fraction respectively

Crystallizer
 Crystallizer Design Procedure
The Following Step are outline for the Design of Crystallizer:
1) Choose the type of crystallizer that must meet the requirement for
a) Product Size
b) Product Quality
c) Process economics
2) Make a list of temp and physical properties required for calculation.
3) Make a Material balance, Heat balance and Flow sheet.
4) Decide what retention time is required to make the required product.
a) By experience
b) From growth and nucleation rate

Reference:Handbook of Industrial Crystallization

 Cont.…
5. Size the body on the basis of controlling volume for crystal retention with due
consideration for minimum cross-section required for vapor release.
6. Size the heat transfer surface.
7. Size the Vapor Pipe.
8. Select the Circulate pump.
9. Select the Agitator.

Reference:
Handbook of Industrial Crystallization
 Crystallizer Designing
1) Retention time Parameters
2) Minimum Active Volume
3) Sizing
4) Height of Cylinder
5) Height of Cone
 Equipment Sizing:
Calculation Flow Diagram

Retention time
r = L 50
3.67G
 Equipment Sizing:
Calculation Flow Diagram

Retention time
Minimum Active Volume
r = L 50 VR = rV 14
3.67G
 Equipment Sizing
Calculation Flow Diagram

Retention time
Minimum Active Volume
r = L 50 VR = rV 14
3.67G

Sizing
VR = Vcone + V cylinder
π
VR = 0.1868D +
3
D 2 (1.5D)
4
 Equipment Sizing:
Calculation Flow Diagram

Retention time
Minimum Active Volume
r = L 50 VR = rV 14
3.67G

Height of Cone
ℎ = t an 55 ( 0 −D 0.1D
)
2 2 Sizing
VR = Vcone + V cylinder
π
VR = 0.1868D +
3
D 2 (1.5D)
Height of Cylinder 4
ℎ = 1.5D
 Mechanical Engineering Design
The selected material for the crystallizer is (stainless steel 316) due to its high
corrosion resistance.

•
Shell Thickness 3
t
Pc = K c E
Do
•
Tori spherical Head Thickness

Pe
e = 4R s
E
 Mechanical Engineering Design

•
Cone Thickness

3
Pc = K c E t cone
L
D

•
Corrosion Allowance: 2 m m
 Mechanical Engineering Design

•
Leg Support, Angle Type

Wt −K 1 + 6K2 + H ( −R
K + 6K )
S 1t = [cosα R 3 4
t2
t

Wt −K 1 − 6K2 + H ( − KR − 6K
S 1c = [cosα R 3 4
t2
t
Mechanical Engineering Design

Figure A.5.4.5.Angle Leg Dimensions

Swirl B r e a k e r
 P i p e a n d N oz z l e S i z i n g
To calculate the diameters of the pipe the following equation is used.
D i , o p t = 3 . 9 q 0.45 ρ 0.13
TECHNO ECONOMIC FEASIABLITY REPORT
NAME OF THE UNIT: P.S. PVT .LTD

LOCATION: Kanpur

REGISTERED OFFICE: UPSIDC, Roma Industrial Area, NH-2 Road, Kanpur

NAME OF THE PARTNER(S): SACHIN KUMAR

PRASHANT SINGH

ITEM OF MANUFACTURE: PRODUCTION OF REFINED RICE BRAN WAX

INSTALLED CAPACITY: 2TPD
PROPOSED CAPACITY FOR THREEONWARDS YEARS OF THE PRODUCTION:
60%, 70%, 80%
POWER REQUIREMENTS: 500unit/day
EMPLOYMENT POTENTIAL: 26nos.
COST OF PROJECT

Entities Calculation Cost

Cost of land 2000×5000 1,00,00,000

1. LAND
Site development charges 10,00,000
Area of land : 2000 sq. M (earth filling , boring etc.)
Circle rate : 5000/sq. M
Registration + Stamp Duty (12.5 + 2)% of cost of land 14,50,000

Total 1,24,50,000
 Entities Cost
 2.BUILDING:
Construction 20,00,000

RCC 5,00,000
Electrification 3,00,000
Other expenses 50,000

Total 28,50,000

3. Machinery and Equipments -:

Entities Cost

2 TPD Hydraullic Press 20,00,000

cost{2}

Boiler, ETP, Chiller, cooling 1,00,00,000

tower

500 kg De oiling section 20,00,000

(solvent extraction.){2}

Total 1,40,00,000
4. Miscellaneous Fixed Assets = 1,00,000

5.Escalation and Contingencies = 10%of (total cost of Building, Machinery & Equipments
and Miscellaneous Fixed Assets)
= 10% of (28,50,000 + 1,40,00,000 + 1,00,000)
= 10% of (1,69,50,000)
= 16,95,000

6. Preliminary and preoperative expense = 1,00,000

7. Interest during Construction Period = 1,00,000

8. Margin Money for Working Capital -:

Entities Calculation Cost

Raw Material 15 x 4,00,000 60,00,000

Goods in 1,00,000
Process
Stock and 15 x 2 x 40,000 12,00,000
Deters
Miscellaneous 15 x 16,566 2,48,500
(Wages)
Total 25% of all the 18,87,125
above entities

Total Cost of Project -: 3,31,82,125

Salaries (per month)-:
Job Description (No. of Employee) Net Salary

Unit head (1) 50,000

Process manager (1) 40,000

Lab Head (1) 40,000
Process Engineers (2) 50,000

Boiler incharges (1) 20,000

Packaging in-charge (1) 25,000

Operators (4) 60,000

Accounts + HR + maintenance + dispatch (3) 1,00,000

Security personnel (4) 40,000

Lab chemists (2) 30,000

Casual workers (6) 42,000

Total 4,97,000
Per day salary 16,566
 Name Amount Cost Net
2.Raw material (per day) -:

Hexane 6,000 kg 40/kg 3,60,000

Crude wax 2,000 kg 20/kg 40,000

Total 4,00,000

3. Packaging Material Requirement(per day) -:

Cost (@ Rs. 1/kg of Wax packed) = 2×1000 = 2000

Name Amount Cost Net

4. Utilities (per day) -:
Steam 2000 kg 2/kg 4,000

Electricity 500 units 14/unit 70,000

Fuel (husk) 500 kg 2/kg 1,000

Other 6,000
Total 81,000
5.Other contingent expenses (per day) -:

Entities Net Amount

Maintenance and repair 1,000

Transportation 5,000

Selling + publicity 2,000

Telephone + Wi-Fi 200

Insurance 500

Stationary , furniture, store 1000

Total 9700
Depreciation (yearly) -:

Entities Calculation Amount

Building 5% of cost of 1,02,500

Building

Machine 15% of cost of 21,00,000

Machinery and
Equipments

Total 22,02,500
7.Miscellaneous expenses (yearly) = (0.5% of daily expenses)
= 17,702.5

8.Interest on term loan (yearly) = (10% of 70% of Total cost of project)

= 23,22,748

9.Interest on working capital (Yearly) = (10% of 75 % of MMWC)

= 1,41,534

10.Total cost of production = (Sum of all the above entities in viability report)
(yearly) = 15,81,58,484.5

11.Sales Realization(annual) -:

A-Wax for selling = 1200kg/day X 300 days = 360,000 kg

Selling price in market = 500/kg
Sale accruals = 360,000 X 500 = 18,00,00,000
 B. Recovery (annual) -:

Entities Amount Cost per Net

unit
Recoverd Oil 776kg/day x 300 days 80/kg 1,86,24,000

Total 1,86,24,000

Total Sales Realization = 19,86,24,000

12. Gross Profit= 19,86,24,000 – 15,81,58,484 = 4,04,65,516

13. Income Tax on Gross Profit -: 30% x 4,04,65,516 = 1,21,39,654

14. Net Profit = 4,04,65,516 – 1,21,39,654 = 2,83,25,862

15. Total Depreciation = 22,02,500

16.Cash accruals = 22,02,500+ 2,83,25,862= 3,05,28,362

Payback Period

Original Investment = -3,31,82,125

Year Cash Inflow Cumulative Cash inflow

0 -3,31,82,125 -3,31,82,125
1 3,05,28,362 -2653763
2 33581198 30927435

In the second year,

Total Amount required to recover in 2nd year = 30927435

Therefore ,recover in 2.079 YEAR

Hence, it would take 2.079 YEAR to recover our original investment i.e. Payback
Period is 2.079 YEAR
Break Even Point

Break-even point = [(FC/ (Sales - VC)) x 100] %

Fixed Cost = 16566 + 6363 + 59 + 9700 = 32,688

Sales = 198624000 / 300 = 662080

Variable Cost = 400000+ 2000 + 81000 + 387 = 4,83,387

Break Even Point = [(32,688/ (662080- 483387)) x 100] %

= [(32688 / 178693) x 100] %
= 18.29%