coco-ethanol production of the hilltop coco products enterprises-updated
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I. INTRODUCTION
Rationale
Practicum is prescribed in the Bachelor of Agricultural
Engineering Technology Curriculum, structured to engage in
varied individual effective experience for each student in
the communities and organizations in the application of
Engineering Technology in Agriculture. This exposes the
students on the application of technologies and theories
they have learned in the classroom with emphasis on farm
mechanization, irrigation and crop processing in order to
mold them to be more effective and globally competitive
future Agriculture Engineering Technicians, trained
efficiently in both theoretical and practice know-how,
envisioned to be the future mentors of the farmers.
Importance of the Practicum
The field practice/practicum experience attributed a
unique opportunity for students to acquire skills in
effective application of agricultural technologies and
develop a professional personality that reflects the values
and ethics of the Agricultural Engineering Technology
Profession in preparation for entry level employment and
efficient technology-based operation of agri-based
enterprises.
Objectives of the Practicum
The conduct of the practicum will provide the
practicumers the opportunity to acquire practical knowledge
in the field, specifically be able to:
1. Gain practical knowledge on the application of
agricultural technologies in coconut farming and
processing;
2. Learn the basics and practical way of producing ethanol
from coconut sap and coconut water;
3. Identify the skills and learnings acquired and problems
encountered by the practicumer during the conduct of
the practicum.
Time and Place of the Practicum
The practicum was undertaken at Sitio Hibabaongan,
Brgy. Washington, Catarman Northern Samar. It was undertaken
from December 2011 to February 2012 or equivalent to 600
working hours, under the supervision of Engr. Jaime P.
Gilbunela (owner) the Engr. Lidany F. Cornillez(Practicum-
adviser).
II. HOST PROFILE
Profile and Organizational Setup
In response to the Biofuel Act of 2006 requiring the
blending of ethanol with gasoline, Department of Science and
Technology (DOST 8) through its Provincial S 8 T Center
(PSTC) in Northern Samar initiated a community based project
entitled, “Establishment of a Coco-Nipa Ethanol Pilot
Production Plant in Northern Samar” with Engr. Jaime P.
Gilbuela, PAIE and Associates as the project proponent. The
project is presently situated at Sitio Hibabaongan, Brgy.
Washington, Catarman Northern Samar.
The Project started in 2009, in cooperation with the
office of congressman Paul R. Daza, the provincial
Government of Northern Samar (PGNS), the University of
Eastern Philippines (UEP), Philippine Coconut Authority
(PCA), the Northern Samar Coconut Industry Development
Council (NSCIDC) and with the financial assistance of DOST
Regional Office No.8 thru its Grant-In-Aid program in the
amount of Fifty Thousand Pesos (P50,000). Engr. Jaine P.
Gilbuela was able to fabricate a boiler and still units and
a blower which is now being used in the production of coco-
ethanol through distillation process.
Trial Test
A preliminary test-run was conducted on February 10,
2010 to test the quality of the locally. Fabricated boiler
and still units and to determine possible adjustment or
modifications preparatory to the final and formal test-run
of the whole production plant. The preliminary test yielded
encouraging and promising results. This give way to the
launching of the first Coco-Nipa Ethanol Pilot production
plant in Northern Samar. The undertaking was attended by the
officials and representatives from the Provincial Government
of Northern Samar. The undertaking was attended by the
officials and representatives from the Provincial Government
of Northern Samar. (PGNS), UEP, PCA, DAR, DTI, DOST-PSTC
Northern Samar and the Northern Samar and the Northern Samar
Coconut Industry Development Council (NSCIDC), Non-
government organizations business groups and the farmers
stake holders as well.
DOST and NSCIDC Inspection
On April 21, 2010, the DOST Inspection Committee and
IDEA Team conducted an inspection of the facilities and
equipment. A test-run was conducted featuring the process of
coco-nipa ethanol production using the locally fabricated
boiler and still units and other improvised auxiliaries
installed in a shade house made of bamboo, indeed a village
level undertaking. The ethanol produced were tested for
cooking, blowtorch operation, fuel blending (10%) for two
stroke engine. The “Lambanog” a low-proof ethanol by product
also served as beverage. DOST 8 facilitated the submission
of product sample to the Industrial Technology Development
Institute (ITDI) of DOST at Bicutan, Taguig City, Metro
Manila for alcohol content analysis.
All tests undertaken during the said activity, also
showed encouraging and promising results to warrant
viability of the project both technically and economically.
Engr. Gilbuela won the first prize for the Likha Award
or outstanding utility model for his “Design and Fabrication
of Equipment to produce Bioethanol from coconut sap” during
the 2011 DOST-Sponsored Regional Invention contest and
exhibition held last August 22-25 2011 in Tacloban City.
Products
The following are the main products produced by the
plant:
a. Primary Products
1. Coco-nipa ethanol fuel(bioethanol)
- Can be blend in gasoline for internal combustion
engines and for household cooking.
2. Coco-nipa low proof beverages
- Commonly known as “lambanog”
3. Coco organic vinegar
- Widely used in every household for cooking,
preservatives and other production using vinegar.
b. Secondary Products
The following are the secondary products produced.
1. Perfumes 5. Wines
2. Colognes 6. Solvents
3. Sanitizers 7. Anti-freeze
4. Energy drinks
III. PRACTICUM
PROGRAM OF ACTIVITIES
Practicum provides opportunities to go through the
actual methodologies of a specific job using the real tools
and equipment and also learn its processing method and
techniques. In effect, the workplace becomes a development
venue for a practicumer to learn from school.
This section narrates the activities that the
practicumer had gone through during the operation. This also
includes observation, participation, and interaction during
their operation. Practicum is an important way in which
students acquire relevant knowledge and skills at work.
The practicum started with an orientation to inform the
practicumer about the plant’s equipment and processing
procedure with the owner, Engr. Jaime P. Gilbuela. The
practicumer were permitted initially to observe the entire
operation. The next operation, the practicumer were allowed
to help the workers. We provided fuel such as wood, coco
shell, and husk to be fed on the furnace and put water into
the tank through its cooling system.
Time came when the practicumer first handled and
operated the machine; the still/column. The practicumer
learned that the still is the principal part wherein a
constant temperature would be maintained during operation.
As a routine before operation…
Observation
The practicumer observed that the brew to be charged
should undergone its fermentation before charging observed
especially the boiler and the container used. The water on
the cooling system should be clean and strained well to
avoid dogging in the pipes. The plant advantage is that
there is no thrown away on the brew being charged.
Participation
The trainee participated in its normal operation of the
plant by checking important spots like the furnace, boiler
and mostly the thermometer in the still. When trouble
happened to the equipment during the progression will cause
a big interruption on the whole process. They participated
also in processing its vinegar.
Interaction
During the training, the practicumer learned to
interact with other people. He knows that people have
different characteristics and attitudes, however, making
friends with the trainee’s co-workers wasn’t make difficult.
Even though he was only a trainee, they didn’t treat
him like trainee but an equal. As a practicumer, he didn’t
feel uncomfortable as he worked with them, form the
interaction the practicumer had with the workers and owner
of the plant, he learned to work with patience. Although
thoroughly working on something was time consuming, the
quality of the output/product is the most important. He also
learned his co-worker’s experiences and mistakes that he can
apply whenever he needed them. They also encouraged the
practicumer to go on with his studies until he become
professional. Although practicumer worked and interact with
them, the skills and techniques that they shared with him
which cannot be found from books.
SIGNIFICANT LEARNING’S AND INSIGHTS
Insights on Coconut Tree
Coconut (Cocos nucifera L.) is a large palm, growing up
to 30 meters (98ft) tall, with pinnate leaves 4-6 meters
(13-20ft) long, and pinnae 60-90cm long; old leaves break
away clearly, leaving the trunk smooth, there dwarf and the
b.) tall variety. There are simply distinguished according
to its height. Dwarf coconuts are usually early maturing. It
produces nuts during its. Earlier years compared to the
tall varieties. Tall varieties however yield more nuts than
dwarf varieties. On very fertile land tall coconut palm tree
can yield up to 75 fruits per year, but more often yields
less than 30 mainly due to cultural practices. (Sarian,
2010)
Like other fruits it has thre layers; exocarp,
mesocarp, and endocarp. The exocarp and mesocarp make up the
husk of the coconut. The mesocap is composed of fiber called
coir which have many traditional and commercial uses. The
shell has three germination pores (stoma) or eyes that
removed. Within the shell is a single seed. When the seed
germinates, the roots of its embryo pushes out through one
of the eyes of the shell. (Child,19)
The endosperm or meat is the white and fleshy edible
part of the coconut. Like most nut meat, coconut meat
contains less sugar and more protein that popular fruits
such as bananas, apples, and oranges. It is relatively high
in minerals such as iron, phosphorus and zinc. The meat in a
green young mature coconut. When the coconut has ripened and
the outer husk has turned brown, a few months later, it will
fall from the palm of its own accord. At that time the
endosperm has thickened and hardened, while the coconut
water has become somewhat bitter.
Coconut water on the other hand serves as a suspension
for the endosperm of the coconut during its nuclear phase of
development, later the endosperm mature and deposit into the
coconut rind during their cellular phase. (Paniappan, 2002)
It is consumed as a refreshing drink and is gaining
popularity as an isotonic sports drink. Mature fruit have
significantly less liquid than young immature coconuts,
barring spoilage. Coconut water can be fermented and
processed into vinegar and alcohol.
The sap derived from incising the flower clusters of
the coconut is drunk as toddy or “tuba” in the Philippines.
Philippines this alcoholic drink is called “Lambanog” or
coconut vodka. A young well-maintained tree can produce
around 300 liters of toddy per year while a forty year old
tree may yield around 400 litters.(Potter, 2005)
Coconut industry in the Philippines
Coconut industry plays a key role in shaping national
development. It is among the top ten export produce of the
country as exhibited by the good export produce of the both
traditional and non-traditional coconut products. About one
third of the country’s avable agricultural land or 3.26
million hectares is planted to coconut. Representing sixty
eight (68) out of 1.554 municipalities in the country. It
provides a sustainable income source for Filipinos by way of
employment generation. Through its many program. (PCA-
Philippine Coconut Authority)
Unfortunately, despite the numerous coconut plantation
in the country, productivity levels remain low and one of
the reasons may be attributed to lack of information on
appropriate technologies for coconut farming(Banzon and
Velaso, 1982)
Coconut products and by-products
Coconut is probably known as the “tree of life” because
of the variety of products and by-products made from the
tree.
1. COPRA – is the dried coconut meat. It is the source
where coconut oil is extracted for many uses.
OIL – extracted processed/filtered oil obtained from
copra.
COCONUT MILK – the liquid obtained by pressing grated
coconut meat.
DESICCATED COCONUT – dried coconut grated meat mainly
prepared from food uses.
COCONUT FLOUR – this is the de-aled desiccated coconut
that is finely grounded.
2. COCONUT SHELL – this is the protective covering of the
coconut meat and water. This makes a very good source
of charcoal. This is very good fuel for domestic
cooking.
ACTIVATED CHARCOAL – found to posses the ability to
absorb gases and vapors. Hence finds uses in gas mask,
cigarette filters, removal of bad odors from air
conditioning, freezers, and refrigerators and many
other absorption capabilities.
CHARCOAL BRIQUETTES – coconut shell charcoal are
processed into briquettes so that it is easier to
transport.
NOVELTY ITEMS – local craftsmen make indigenous
novelties from shells such as lamps, figurines, picture
frames, musical instrument, souvenirs and many more.
3. COCONUT HUSK - Fibrons outer covering of the nut, this
part extent from nut skin to the shell and varying
thickness up to 5cm.
COCO COIR – the hair-like thread extracted from the
coconut husk by mechanical method or by the
decorticating machine.
COCO DUST – are the medium collected after separating
the coir from the husk.
4. COCONUT WATER – the liquid found inside the coconut. It
is the excellent and readily available drinking water.
The quality of water varies according to the age of the
nut. Younger nut water is largely consumed locally as
beverage. Water from nature nuts is used as raw
material from making nata de coco, vigegar, intravenous
fluid, and lector cyte, wine and alcohol.
5. COCONUT SAP – a very sweet juice obtained from a young
inflorescence locally known as “tuba.”
LIQUOR – coco sap are left to ferment and made into
alcoholic beverage called “tuba”. In Samar and Leyte
Province, they add bark from a local tree and ferment
to produce “Bahalina”. In Southern Tagalog and Bicol
Area, Coco sap are distilled and made into a strong
alcohol called “Lambanog.”
VINEGAR – coco sap are also made into vinegar.
COCO SUGAR – coco sap are sometimes cooked to produce
sugar. This has been a long practice in some places but
not in very large quantities.
COCO ETHANOL PRODUCTION PROCESS
The production of the coco-ethanol and its by products
undergoes the following processes.
FEEDSTOCK PREPARATIONCOCO SAP/ WATER
BREW FERMENTATION
DISTILLATION
END PRODUCT COLLECTION
EQUIPMENT USED
The following are the equipment used in the system:
1. Boiler and furnace with chimney
2. Still – bubbler, vapor stripper, condenser (reflex
section)
3. Cooling system with cooling tower
4. Other accessories
a. Batch charging tank c. Fermentation tank
b. Residue receiving tank d. Product containers
Coco ethanol production process first takes place by
collecting coco sap from the farmers. The sap, measuring ten
(10) gallons (37.870 liters) were added with two (2)
kilogram brown sugar and four (4) tablespoon of yeast. The
brew were cleaned and covered in a container for 6 days
fermentation. In fermentation of the brew, the sugar and
yeast are partially converted to alcohol. Next were charging
the brew into the boiler tank in preparation for
distillation.
To separate the ethanol on the brew, distillation
process/method was used. The brew were distilled at a
temperature of 78.4 0C, the boiling point of ethanol then
the brew to be distilled is heated in the boiler. Ethanol
which has the lowest temperature than water were first turn
into a vapor. The vapor enters the condenser, where it cool
and becomes a liquid again. The collected through a receiver
and drips finally to the container.
The second dripping faucet is a mixture of water and
ethanol called low proof ethanol which drips simultaneously
with the ethanol.
In order to maintain the temperature of the still, it
uses three kinds of cooling system; of which are water and a
controlled air passage into furnace. The first water cooling
system was constantly poured inside the still as soon as
vaporization takes place. If the first cooling system could
not sustain the rise in temperature. The later cooling
system, water and controlled air passage will then be used.
As soon as ethanol was observed to degenerately
dripped, distillation process could be ended to acquire a
good quality ethanol and leaving a small percentage of
alcohol to the residue.
Finally, the residue inside the boiler were left to cool
and drained the day after. Straining it while the residue
collected would be necessary making it dirt free. Sugar and
yeast as desired by the volume of the residue for vinegar
processing.
SKILLS AND KNOWLEDGE OBTAINED
While operating at the plant, the practicumers find a
way to learn experiences at the same time. “Training by
doing” this is...
V. PROBLEMS ENCOUNTERED AND RECOMMENDATIONS RELATED TO THE
PRACTICUM.
Problems Encountered
The problems that the practicumers encountered during
his training were all related to the plant’s operation.
Gathering the coco sap to the farmers are often difficult,
the coco sap needed are sometimes not acceptable and sub-
standard thus interrupt the fermentation process.
For fuel used the operation are sometimes wet due to
weather conditions mostly raining.
Weather condition could also affect the operation,
maintaining the temperature of the thermometer of the still
is flexible when the surrounding temperature are too hot and
cold.
Recommendations
Based on the observed operations, the practicumers
recommends the following:
A gradual feeding of fuel such as wood, coco shell, and
coco husk to the furnace should be done in order to
maintain its temperature.
Because distillation is the major energy-consuming
stage, such new technology should sought to improve
preferably more advance.
The trainee further recommends an innovation or its
cooling system in aid of controlling evenly the
temperature during operation.
A seminar should be conducted to the farmers
specifically to the coco sap collector for proper
handling and collecting the coco sap.
COCO ETHANOL PRODUCT COST
PARTICULARS PRICE/UNIT QUANTITY TOTAL
Coconut sap P 10.00/li 40 li P 400.00
Brown Sugar P 35.00/li 2 kl P 70.00
Yeast P 1.00/gram 4 g P 4.00
Labor (Operator) P 300.00/Operation 1 person P 300.00
Labor (Helper) P 200.00/Operation 1 person P 300.00
Fuel P 100.00/ Distillation P 100.00
Total Cost P1074.00
Estimated selling price of the product
Distillation
Product
Selling
price
% recovery
for 10 gal
of products
Recover
ed
volume
Total
Ethanol (H.P.)
Ethanol (L.P.)
Organic vinegar
60/ li
60/ li
25/ li
8%
15%
6%
3.2 li
6 li
30.4 li
P192.00
P360.00
P760.00
Total Product Price P1312.00
Net Income of Distillation 1312.00
1074.00
P238.00
Monthly Net Income Per
15 Distillation Run 238 x 15 = P3570.00
Year Net Income 3570x12 = P42840.00
COCO-ETHANOL PRODUCTION OF THE HILLTOPCOCO PRODUCTS ENTERPRISES
PRACTICUM-TERMINAL REPORT
CORADO, William L.GALONO, Domingo V.
Practicum-terminal submitted in partial fulfillment of the requirement for graduation for the degree of Agricultural Engineering Technology University of Eastern Philippines, College of Engineering, Research Contribution No._____ prepared at the University of Eastern Philippines, University Town, Northern Samar under the supervision of Engr. Lidany Fi Cornillez from December 2011 to February 2012.
March 2012
TABLE OF CONTENTS
Acknowledgment
I. Introduction 1
Rationale 1
Importance of the Practicum 1
Objective of the Practicum 2
Time and Place of the Practicum 2
II. Host Profile 4
Organizational Set up 4
Products 6
Plant Layout 7
III Practicum – Program Activities 8
Significant Learning and Insights Skills and
Knowledge Obtained
-coco ethanol production process
9
IV Significant Insights 13
V Problems Encountered and Recommendation
Related to the Practicum
23
Appendices
Pictorials
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