wet mass production of algal bio-diesel
TRANSCRIPT
Wet Mass Production Of Algal Bio-Diesel
B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 1
Table of Contents
1. Company profile…………………………………………....2
2. Acknowledgement………………………………………….3
3. Abstract…………………………………………………….4
4. Introduction………………………………………………...5
5. Algae Culture Systems……………………………………..8
6. Integrated Biodiesel production From Algae………………9
7. Algae Biodiesel Opportunities In India…………………….11
8. Executive Summary……………………………………… 12
9. Business Model…………………………………………….14
10. Funding…………………………………………….…17
11. Marketing…………………………………………….17
12. Rupee Analysis……………………………………….21
13. ROI Analysis…………………………………………22
14. Technology…………………………………………...24
15. Engine Testing……………………………………......34
16. Engine Testing Conclusions…………………………..39
17. Engine Testing Results………………………………..45
18. Calculation Of Parameters…………………………….45
19. Overall Conclusion……………………………………48
20. Human Resource………………………………………49
21. Future Work……………………………………………49
22. Photos…………………………………………………. 50
23. References……………………………………………...55
Wet Mass Production Of Algal Bio-Diesel
B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 2
List Of Tables
1. Funding………………………………………………………………..17
2. Engine Specifications………………………………………………….34
3. Result & Comparision…………………………………………………40
4. Engine Testing Results………………………………………………...45
List Of Figures
1. Integrated Biodiesel Production From Algae………………………….9
2. Break Even Analysis Chart……………………………………………21
3. Process Flow Chart……………………………………………………26
4. Nano Particle Characterization………………………………………..32
5. Effect Of Catalysts…………………………………………………….33
6. Sensitivity Analysis Of Water…………………………………………34
7. Comparisons Graph……………………………………………………41
8. Data Acquisition……………………………………………………….46
Wet Mass Production Of Algal Bio-Diesel
B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 3
GrnTech Fuels
pvt Ltd
NITISH KUMAR : Managing Director
SANDEEP SHANTHARAM : Scientist
Wet Mass Production Of Algal Bio-Diesel
B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 4
ACKNOWLEDGEMENTS
This is to show our gratitude towards all those who helped and guided us for the
successful completion of our CTE capstone projectproject.
It has been our fortune to be associated with Prof.Nitin Kulkarni., Director of CTE.
As our project guide we express our sincere gratitude to Prof,V.S.Hombalimat for
his motivation, inspiration, guidance, constructive criticism and support during the
present work. His words of encouragement and unconditional dedication will
always be cherished.
We are thankful to our HOD L.R.Patil., who assisted us in handling the equipment
and leading our project to success.
We also are extremely thankful to our principal and vice principal for providing
such a wonderful CTE platform for a carving career.
Wet Mass Production Of Algal Bio-Diesel
B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 5
Abstract
In context of climatic changes and soaring prices per barrel of petroleum,
renewable carbon neutral, transport fuels are needed to displace petroleum derived
transport fuel, which contribute to global warming and are of limited availability.
Biodiesel derived from oil crop is a potential renewable and carbon neutral
alternative to petroleum fuel. Unfortunately, biodiesel from oil crop, waste cooking
oil and animal fat cannot realistically satisfy even a small fraction of the existing
demand for transport fuel. As demonstrated here, biodiesel from microalgae seem
to be the most promising renewable biofuel that has the potential to completely
displace petroleum-derived transport fuel without adversely affecting supply of
food and other crops products. Like plants, microalgae use sunlight to produce oil
but they do so more efficiently than crop plants. Oil productivity of many
microalgae greatly exceeds the oil productivity of the best producing oil crops. The
present review covers the approach for making algal biodiesel more economically
and competitive with petrodiesel.
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B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 6
INTRODUCTION
Algae have recently received a lot of attention as a new biomass source for the
production of renewable energy. Some of the main characteristics which set algae
apart from other biomass sources are that algae (can) have a high biomass yield per
unit of light and area, can have a high oil or starch content, do not require
agricultural land, fresh water is not essential and nutrients can be supplied by
waste-water and CO2 by combustion gas.The first distinction that needs to be
made is between macroalgae (or seaweed) versus microalgae. Microalgae have
many different species with widely varying compositions and live as single cells or
colonies without any specialization. Although this makes their cultivation easier
and more controllable, their small size makes subsequent harvesting more
complicated. Macroalgae are less versatile, there are far fewer options of species to
cultivate and there is only one main viable technology for producing renewable
energy: anaerobic digestion to produce biogas. Both groups will be considered in
this report, but as there is more research, practical experience, culture and there are
more fuel options from microalgae, these will have a bigger share in the report.
First, existing biofuel sustainability standards are analysed for applicability,
followed by a thorough analysis of the opportunities and risks of ABB
sustainability. Secondly, sustainability is discussed in the context of potential and
threats for developing countries.Microalgae comprise a vast group of
photosynthetic, auto/heterotrophic organism which has an extraordinary potential
for cultivation as energy crops. These microscopic algae use photosynthetic
process similar to that of higher-developed plants. They are veritable miniature
biochemical factories, capable of regulating carbon dioxide(CO ), just like
terrestrial plants .In addition, these micro-organisms are useful in bioremediation
applications and as nitrogen fixing biofertilizers.This review article discusses the
potential of microalgae for sustainably providing biodiesel for the displacement of
petroleum derived transport fuels in India. The need of energy is increasing
continuously, because of increase in industrialization as well as human population.
The basic sources of this energy are petroleum, natural gas, coal, hydro and nuclear
.The major disadvantage of using petroleum based fuel is atmospheric pollution.
Petroleum diesel combustion is a major source of greenhouse gases (GHG). Apart
from these emissions, petroleum diesel combustion is also major source of other air
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B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 7
contaminants including NOx, SOx, CO, particulate matter and volatile organic
compounds which are adversely affecting the environment and causing air
pollution. These environmental problems can be eliminated by replacing the
petroleum diesel fuel with an efficient renewable and sustainable biofuel. Algal
biomass is one of the emerging sources of sustainable energy. The large-scale
introduction of biomass could contribute to sustainable development on several
fronts, environmentally, socially and economically .The biodiesel generated from
biomass is a mixture of mono-alkyl ester, which currently obtained from
transesterification of triglycerides and monohydric alcohols produced from various
plant and animal oils. But this trend is changing as several companies are
attempting to generate large scale algal biomass for commercial production of algal
biodiesel.
Biodiesel is non-toxic and biodegradable alternative fuel that is obtained from non-
renewable sources. In many countries, biodiesel is produced mainly from
soybeans. Other sources of commercial biodiesel include canola oil, animal fat,
palm oil, corn oil, waste cooking oil. But the recent research has proved that oil
production from microalgae is clearly superior to that of terrestrial plants such as
palm, rapeseed, soybeans or jatropha . Important advantage of microalgae is that,
unlike other oil crops, they can double their biomass within 24 hr. the biomass
doubling time for microalgae during exponential growth can be as short as 3 to 4
hr, which is significantly quicker than the doubling time for oil crops .It is for this
reason microalgae are capable of synthesizing more oil per acre than the terrestrial
plants which are currently used for the fabrication of biofuels. In the production of
energy from micro algal biomass, two basic approaches are employed depending
on the particular organism and the hydro-carbon which they produce. The first is
simply the biological conversion of nutrients into lipids or hydrocarbons. The
second procedure entails the thermo-chemical liquefaction of algal biomass into
lipid or hydrocarbons. Lipids and hydrocarbons can normally be found throughout
the micro algal biomass. They occur as membrane components, storage products,
metabolites and sources of energy for microalgae. Algal strains, diatoms, and
cyanobacteria (categorized collectively as microalgae) have been found to contain
proportionally high level of lipid (over 30%). These microalgal strains with high
lipid content are of great interest in search for sustainable feedstock for production
of biodiesel. The global economy literally runs on energy. An economic growth
combined with a rising population has led to a steady increase in the global energy
demands. If the governments around the world stick to current policies, the world
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B.V.Bhoomaraddi College Of Engg & Tech -CTE Capstone Project Page 8
will need almost 60% more energy in 2030 than today, of this 45% will be
accounted by China and India together. Transportation is one of the fastest growing
sectors using 27% of the primary energy .The continued use of fossil fuels is not
sustainable, as they are finite resources , and their combustion will lead to
increased energy-related emissions of green house gases (GHG) viz., carbon
dioxide (CO2), sulfur dioxide (SO2) and nitrogen oxides (NOx). The future
reductions in the ecological footprint of energy generation will reside in a multi-
faceted approach that includes nuclear, solar, hydrogen, wind, and fossil fuels
(from which carbon is sequestered), and biofuels .Biofuel can be broadly defined
as solid, liquid, or gas fuel consisting of, or derived from biomass. Rudolph Diesel
first demonstrated the use of biodiesel from a variety of crops in 1900. However,
the widespread availability of inexpensive petroleum during the 20th century
determined otherwise. Generally, shifting society’s dependence away from
petroleum to renewable biomass contributes to the development of sustainable
industrial society and effective management of GHG . A major criticism often
leveled against biomass, particularly against large-scale fuel production, is that it
will consume vast swaths of farmland and native habitats, drive up food prices, and
result in little reduction in GHG emissions. However, this so-called “food versus
fuel” controversy appears to have been exaggerated in many cases. Credible
studies show that with plausible technology developments, biofuels could supply
some 30% of global demand in an environmentally responsible manner without
affecting food production. At the moment, only biodiesel and bioethanol are
produced on an industrial scale. They are the petroleum replacement for internal
combustion engines, and are derived from food crops such as sugarcane, sugar
beet, maize (corn), sorghum and wheat, although other forms of biomass can be
used, and may be preferable. The most significant concern is the inefficiency and
sustainability of these first generation biofuels. In contrast, the second generation
biofuels are derived from non-food feedstock. They are extracted from microalgae
and other microbial sources, ligno-cellulosic biomass, rice straw and bio-ethers,
and are a better option for addressing the food and energy security and
environmental concerns. Microalgae, use a photosynthetic process similar to higher
plants and can complete an entire growing cycle every few days. In fact, the
biomass doubling time for microalgae during exponential growth can be as short as
3.5h. Some microalgae grow heterotrophically on organic carbon source. However,
heterotrophic production is not efficient as using photosynthetic microalgae,
because the renewable organic carbon source required is ultimately produced by
photosynthetic crop plants. Microalgae are veritable miniature biochemical
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factories, and appear more photosynthetically efficient than terrestrial plants and
are efficient CO2 fixers . The ability of algae to fix CO2 has been proposed as a
method of removing CO2 from flue gases from power plants, and thus can be
used to reduce emission of GHG. Many algae are exceedingly rich in oil, which
can be converted to biodiesel. The oil content of some microalgae exceeds 80% of
dry weight of algae biomass . The net annual harvest of algal biomass cultivated in
subtropical areas can be as high as 40 tons ha-1(dry matter), even higher if CO2 is
supplied . It is possible to produce about 100 g m-2 d-1 of algal dry matter in
simple cultivation systems .In theory, high oil content algae could produce almost
100 times of soybean per unit area of land [19]. The calculations made by Chisti
clearly demonstrate the strong scenario for microalgal biofuels. The use of algae as
energy crops has potential, due to their easy adaptability to growth conditions, the
possibility of growing either in fresh- or marine waters and avoiding the use of
land. Furthermore, two thirds of earth’s surface is covered with water, thus algae
would truly be renewable option of great potential for global energy needs. This
paper aims to analyze and promote integration approaches for sustainable
microalgal biodiesel production, with engine compatibility based on ASTM
standards.
Algae culture systems
Culture systems are very different between macroalgae (seaweed) and microalgae.
Because of their small (μm) size, microalgae have to be cultivated in a system
designed for that purpose (placed on land or floating on water), while seaweed can
be grown directly in the open sea. The first mention of seaweed culture dates back
to 1690, in Japan (Tamura in Buck and Buchholz, 2004). Japan and China are still
the main producers of cultured seaweed. Seaweed is mainly used as a food product,
either eaten directly, or used in many processed foods as stabilizers or emulsifiers.
Besides culturing seaweed, part of the current seaweed production comes from
harvesting natural populations or collecting beach-cast seaweed. Besides the
disturbance of the ecosystem by these practices, they are clearly unsustainable for
application on a very large scale. Therefore growing macroalgae in a dedicated
cultivation system is worth considering. For microalgae, the development of
dedicated culture systems only started in the 1950s when algae were investigated
as an alternative protein source for the increasing world population. Later, algae
were researched for the interesting compounds they produce, to convert CO2 to O2
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during space travel and for remediation of wastewater. The energy crisis in the
1970s initiated the research on algae as a source of renewable energy. For algae to
grow, a few relatively simple conditions have to be met: light, carbon source,
water, nutrients and a suitably controlled temperature. Many different culture
systems that meet these requirements have been developed over the years,
however, meeting these conditions for scaled systems is difficult. One important
prerequisite to grow algae commercially for energy production is the need for
largescale systems which can range from very simple open air systems on- or
offshore which expose the algae to the environment, to highly controllable,
optimized but more expensive closed systems. The necessary technology for
developing profitable algae-based fuel generation is still in various states of
development and the final configuration is yet to be determined and demonstrated
at the industrial scale.
Integrated Biodiesel Production for Microalgae
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The key for large scale production of biofuels is to grow suitable biomass species
in an integrated biomass production conversion system (IBPCS) at costs that
enable the overall system to be operated at a profit. The illustration in Figure 1 is a
conceptual model for integrated biomass production [17] that can be adopted for
microalgal biodiesel production. The design of an IBPCS requires the combination
and optimization of several factors such as biomass culture, growth management,
transport to conversion plants, drying, product separation, recycling, waste (liquid
and solid) management, transport of saleable products and marketing. These
factors can be simplified and reduced to three main groups; culturing of
microalgae, harvesting and processing of biomass. In the idealized case, the
conversion plants are located in or near the biomass growth areas to minimize the
cost of transporting biomass to the plants, of which all the non fuel effluents are
recycled to the growth areas as demonstrated in Figure. The growth can be
implemented in a microalgal farm. It would be equivalent to an isolated system
with inputs of sunlight, air, CO2, and water. Nutrients are replenished based on
their status in the growth media and the environmental controls and waste disposal
problems are minimized.
Approximately, half of the dry weight of microalgal biomass is carbon [21], which
is typically derived from CO2. Thus, producing 1 kg of algal biomass fixes 1.6 –
1.8 kg of CO2.The CO2 must be fed continuously during daylight hours. Thus, an
algae farm can be located adjacent to a power plant for utilizing CO2 from the
combustion process [17, 19, 22]. In such a circumstance, management of other
gaseous emissions and wastewater by algal culture is also possible. It is because
algae can remove effectively nitrogen, phosphorus, and heavy metals such as As,
Cd, and Cr from aqueous Int. J. Mol. Sci. 2008, 9 1191solutions [19, 23]. Since
emission control and wastewater management are costly and technically
demanding, the use of wastewater as a source of nutrients for algae production,
coupled with wastewater treatment are added environmental and economic
benefits. The algal biomass produced needs to be further processed to recover the
biomass. A problem associated with algal biomass is the relatively high water
content. It normally requires pre-treatments to reduce the water content and
increase the energy density. This requirement consequently increases the energy
cost. However, direct hydrothermal liquefaction in sub-critical water conditions
can be employed to convert the wet biomass to liquid fuel without reducing the
water content. Overall, by adopting integration approaches, such as wastewater
treatment, nutrients and heavy metals recovery by algae culture, whereby
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additional economic benefits are created the obstacle of high cost of biodiesel
production from algae may be overcome.
Algal Biodiesel Opportunities In INDIA
India is a rapidly expanding country in terms of both its population and its
economy. According to CIA (Central intelligence agency) Fact book, India's
current population is about 1,166,079,217 (Till July 2009). Although India
occupies only 2.4% of the world's land area, it supports over 15% of the world's
population. Demographics indicate the population will grow because almost 40%
of Indians are younger than 15 years of age and are likely to produce offspring. By
2050, United Nations' demographer's project that India will have added another
530 million people for a total of more than 1.5 billion. If India continues on its
projected demographic path, it will overtake China by 2045, becoming the world's
most populous country. Economic growth in India, as in many developing and
developed countries, is currently correlated with increased energy consumption.
The environmental issues often discussed in public policy debates in India arise
because of two factors, the sectors responsible for energy use and where economic
development is happening.
Although a large proportion of Indians (approximately 70%) live in 550,000 rural
villages, urbanization levels have increased consistently since 1971. Many Indians
have began congregating in large cities as evidenced by the fact that cities with at
least a million people increased from 12 in 1981 to 23 in giant conglomerates
Mumbai (12.57 million), Calcutta (10.92 million), Delhi (8.38 million), Chennai
(5.36 million) and Bangalore (4.09 million) [56]. In Delhi this has increased the
number of registered vehicles to increase from 841,000 in 1985 to over 3.5 million
in 2001 [57]. As the consequence of India's rapid economic growth there is severe
increase in air and water pollution, deforestation, water shortages, and carbon
emissions. The country's carbon emission is also rising due to rapid
industrialization, transportation sector growth, and the wide-spread use of coal as a
fuel. Due to this large amount of urbanization and industrialization there is sudden
rise in utilization of nonrenewable energy sources, which can cause large amount
scarcity of these fuels in future. So to prevent such conditions there is an urgent
need for alternative sources of energy. According to current research, microalgae
seem to be the promising renewable source of energy for India.
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Petroleum diesel fuel has been sold at government subsidized rates in India to keep
the transport costs low and increase GDP. Currently, a liter of gasoline normally
costs 2.5 times more than a liter of diesel fuel. Taking advantage of this cost
differential, Indian car manufacturers have been investing heavily in the production
of diesel vehicles. As such, there are a substantial number of vehicles on the road
that demand diesel and would not require the relatively expensive retrofits needed
to use Compressed Natural Gas (CNG). The final factor making biodiesel
production in India attractive is the potential to cultivate cheap feedstocks. India's
tropical climate is conducive to grow various species of micro-algae, which serves
as natural benefit over other countries for the production of algal biodiesel. The
micro-algae produced sufficient quantity of biodiesel to completely replace
petroleum. While traditional high oil crops, such palm can produce 2000 to 2500
liter of biodiesel per acre, algae can yield 19,000-57,000 liter per acre. So the
adoption of large-scale biodiesel production and consumption can potentially
lowers India's dependence on foreign countries for oil and helps improve air
quality in major cities like Delhi, Kolkatta, Bengaluru, Chennai, reclaims unusable
wastelands, employs unemployed Indians, and keeps the country's economy on
track for its planned 8 to 10% annual GDP growth according to 11 five year plan
of India.
Executive Summary
Biodiesel is a growing buzz word in the energy market. Discussion about the
current state of energy production and availability has led to government
restrictions and customer awareness of bad practices. Recent studies have shown
that acre for acre, algae is the most efficient source of lipids for the production of
biodiesel. Growing concern over CO2 emissions has led to an increase in
awareness of harmful greenhouse gases in plant effluent streams. Many solutions
have been devised to remedy this problem. However, many of these carbon capture
and sequestration methods are too expensive. Thus, we have developed a cost
effective and sustainable solution. Utilizing an algae photobioreactor, the carbon
dioxide can be captured and converted into oxygen and algal biomass. This
biomass can then be converted into a useful biodiesel using a process that we have
developed. Not only our photobioreactor eliminate the carbon dioxide , it can also
quickly pay for itself from the valuable biomass produced. Pending legislature for
more stringent regulation on CO2 emissions will bring about a strong demand for
cost effective carbon capture and sequestration techniques. We will be ready to
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penetrate the market early and develop relationships with major chemical and
energy companies. Additionally, we will develop solutions for smaller companies
with diesel utility units. We will be able to adapt our design to nearly any
application and therefore service both large and small companies producing. We
will require initial startup capital. This will cover cost for research and
optimization of our biodiesel production process. Additionally, this capital will
allow us to begin several smaller scale installations at local power and energy
companies who are interested in reducing CO2 and reaping the rewards of
biodiesel production.
Need
In the near future, in or around 2020 the fossil fuels are going to be depleted, so we
are striving to provide an alternate solution to it.
International price hike
Fuel crisis
Environmental pollution
Power source for industry
Value Proposition
Our project aims at production of the good quality biodiesel from algae (as a
source). The process is as follows-
A. Cultivation
B. Harvesting
C. Oil extraction
D. Trans-esterification
Our product is Eco-friendly
Economic
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It is accessible by all strata of the society
Business Model
Revenue is generated by direct selling of our product and the by-product
with minor modifications.
We price our product based on 20% margin of the manufacturing cost.
Sales Strategy
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Advertising – a mass media approach to promotion
Outdoor
Business directories
Magazines / newspapers
TV / cinema
Radio
Newsagent windows
Public relations - using the press to your advantage
Press launches
PR events
Press releases
Direct marketing - taking the message directly to the consumer
Mail order catalogues
Bulk mail
Personalized letters
Telemarketing
Point of sale displays
Packaging design
Digital marketing – new channels are emerging constantly
Company websites
Social media applications such as Face book or Twitter
Blogging
Mobile phone promotions using technology such as Bluetooth
YouTube
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E-commerce
Funding requirements:
Serial
No. Item Amount (Rs)
01 Aquarium 6000/-
02 Accessories 2000/-
03 Pump 1000/-
04 Reagents and Contingency 3500/-
05 Miscellaneous 2500/-
TOTAL 15,000/-
Marketing:
Marketing collateral is considered as the collection of media used to support the
sales of product or service. In our case there is no marketing needed as we are
going to tie up with any of the fuel industry and it addresses the worldwide
problem of fuel crisis.
In case if marketing collateral is to be done it will be done as follows:
Sales brochures and other printed product information.
Visual aid used in sales presentation.
Web content.
Sales scripts.
Demonstration scripts.
Product datasheets.
Business cards.
Complimentary packing slips.
E-marketing.
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Business Card
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Advertisement:
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Competitors
Petroleum & Diesel units
Small scale biodiesel production units
Hybrid automotive sectors
Electric vehicle production units
Competitive Analysis
Despite having strong competitors, we still have great potential to be successful as
the market for this product is growing rapidly. It will be impossible for one single
organization to control the entire market because of its vast size. Besides that
Uniqueness
This product provides unique value due to the design for use. This directs the use
of algae based biodiesel production to a new market. Additional tailoring to the
individual customer provides a solution specific to the needs of specific power
generation facilities. This freedom provides a much broader range of applicability
and the ability to expand from just a single design to a design that is workable for a
variety of other sites and power plants.
Abundance of raw materials
Low price value
Eco-friendly
Renewability
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Rupee Analysis:
Approximate breakeven point (calculated in INR):
For calculation using formula method
Sale prize per unit = Variable expenses + Fixed expenses + Profit
79(x) = 2.5(x) +2700000+0 [profit till breakeven point is taken as 0 INR]
x= 35295 units. [Where x*= Number (Quantity) of units sold.]
Total cost/ Revenue= 2788305
Total variable cost= 88237.5
Average cost per unit= 79
[Note: sample space is for 2000 ltrs in lab scale, hence during scale up the cost will
be reduced up to Rs.45]
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Graph of Cost v/s sales
Calculation of return of investment (ROI) and payback period (PP)
The following formulas are used to calculated ROI and PP:
ROI =[Annual gross profit/Capital investment]x 100%
where
Annual gross profit = Annual production income -TAC
and
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Payback period = Fixed capital investment/(Annual after-tax cash flow)
where
Annual after tax cash flow =Annual income-Annual operating cost- Tax
+Tax credit
Fixed Capital Investment = 3000000/-
Operating Cost = 88237/-
Break Even Point = 35295litres
Sales Target = 2000litres/month
After the end of two years
Profit = [48000-35295]x79
= 1003695rs
Tax to Biodiesel = 10%
Tax Credits = 0
1. Annual Gross Profit = 903325.5rs
2. ROI = 30.11%
3. Annual TAC = 724755.95rs
4. Pay Back Period = 4.13years
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Technology
Strains used- Nanochloropsis Occulatta
Chlorella pyrenoidosa
Scenedesmus
Production of Microalgal Biomass
The production of microalgal biodiesel requires large quantities of algal biomass.
Most of algal species are obligate phototrophs and thus require light for their
growth. Several cultivation technologies that are used for production microalgal
biomass have been developed by researchers and commercial producers. The
phototropic microalgae are most commonly grown in open ponds and
photobioreactors. The open pond cultures are economically more favorable, but
raise the issues of land use cost, water availability, and appropriate climatic
conditions. Further, there is the problem of contamination by fungi, bacteria and
protozoa and competition by other microalgae. Photobioreactors offer a closed
culture environment, which is protected from direct fallout, relatively safe from
invading microorganisms, where temperatures are controlled with an enhanced
CO2 fixation that is bubbled through culture medium. This technology is relatively
expensive compared to the open ponds because of the infrastructure costs. An ideal
biomass production system should use the freely available sunlight. It is reported
the best annual averaged productivity of open ponds was about 24 g-1 dry weight
m-2 d-1. A productivity of 100 g-1 dry weight m-2 d-1 was achieved in simple 300
l culture systems. This level has been viewed as deriving from the light saturation
effect. The light requirement coupled with high extinction coefficient of
chlorophyll in algae has necessitated the design and development of novel system
for large scale growth. Experiments have also elucidated that algal biomass
production can be boosted by the flashing light effect, namely by better matching
photon input rate to the limiting steps of photosynthesis. Indeed, the best annual
averaged productivity has been achieved in closed bioreactors. Tridici has
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reviewed mass production in photobioreactors. Many different designs of
photobioreactor have been developed, but a tubular photobioreactor seems to be
most satisfactory for producing algal biomass on the scale needed for biofuel
production. Closed, controlled, indoor algal photobioreactors driven by artificial
light are already economical for special high-value products such as
pharmaceuticals, which can be combined with production of biodiesel to reduce
the cost.
THE OVERALL PROCESS FLOW CHART
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Direct Liquefaction of Algae for Biodiesel Production
The microalgal biomass has relatively high water content (80-90%) and this is
major bottleneck for usage in energy supply. As most other virgin biomass, the
high water content and inferior heat content Int. J. Mol. Sci. 2008, 9 1192
makes the microalgal biomass difficult to be used for heat and power generation.
Thus necessitating pre-treatments to reduce water content and increase the energy
density. As consequence the energy cost increases and makes the alternative less
economically attractive. Direct hydrothermal liquefaction in sub-critical water
conditions is a technology that can be employed to convert wet biomass material to
liquid fuel. This technology is believed to mimic the natural geological processes
thought to be involved in the formation of fossil fuel, but in the time scale of hours
or even minutes. A number of technical terminologies have been used in the
literature to refer to this technology, but it essentially utilize the high activity of
water in sub-critical conditions in order to decompose biomass materials down to
shorter and smaller molecular materials with a higher energy density or more
valuable chemicals. Goudriaan et al. [32] claim the thermal efficiency (defined as
the ratio of heating values of bio-crude products and feedstock plus external heat
input) for the hydrothermal upgrading process (HTU®) of biomass of a 10 kg dry
weight h-1 pilot plant is as high as 75%. The main product of the process is bio-
crude accounting for 45% wt. of the feedstock on dry ash free basis, with a lower
heating value of 30-35 MJ kg-1, which is compatible with fossil diesel and can be
upgraded further. As moist biomass can be easily heated by microwave power, a
process similar to the HTU® process using a novel microwave high-pressure
(MHP) reactor has been developed in order to further minimize the energy
consumption of the process. In addition, integrated utilization of high temperature
and high pressure conditions in the process of hydrothermal liquefaction of wet
biomass would significantly improve the overall thermal efficiency of the process.
Suitable systems for such utilization are an internal heat exchanger network, or a
combined heat and power (CHP) plant. A thermodynamic study, for example, has
been performed to calculate the energy efficiency of the HTU process on the basis
an integrated heat exchanger network. Past research in the use of hydrothermal
technology for direct liquefaction of biomass was very active. Only a few of them,
however, used algal biomass as feedstock for the technology. Minowa etal. [35]
report an oil yield of about 37% (organic basis) by direct hydrothermal liquefaction
at around 300°C and 10 MPa from Dunaliella tertiolecta with a moisture content
of 78.4 wt%. The oil obtained at a reaction temperature of 340°C and holding time
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of 60 min had a viscosity of 150–330 mPas and a calorific value of 36 kJ g−1,
comparable to those of fuel oil. The liquefaction technique was concluded
to be a net energy producer from the energy balance. In a similar study on oil
recovery from Botryococcus braunii, a maximum yield 64% dry wt. basis of oil
was obtained by liquefaction at 300°C catalyzed by sodium carbonate [23]. Also,
Aresta et al. [36-37] have compared different conversion techniques viz.,
supercritical CO2, organic solvent extraction, pyrolysis, and hydrothermal
technology for production of microalgal biodiesel. The hydrothermal liquefaction
technique was more effective for extraction of microalgal biodiesel than using the
supercritical carbon dioxide. From these two studies, it is reasonable to believe
that, among the selected techniques, the hydrothermal liquefaction is the most
effective technological option for production of bio-diesel from algae.
Nevertheless, due to the level of limited information in the hydrothermal
liquefaction of algae, more research in this area would be needed.
Cultivation
Biodiesel is an attractive fuel for diesel engines that it can be made from any
vegetable oil (edible or non edible oils), used cooking oils, animal fats as well as
microalgae oils. It is a clean energy, renewable, non toxic and sustainable
alternative to petroleum based fuels, and it is able to reduce toxic emissions when
is burned in a diesel engine. The interest of this alternative energy resource is that
fatty ester acids, known as biodiesel, have similar characteristics of petro-diesel oil
which allows its use in compression motors without any engine modification.
We cultivated the algae in the shake flask as if it is under the submerged
fermentation phase. We used the F2 medium for the cultivation of these algae.
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Methodology
We prepared 100ml of the F2 media and autoclaved it to avoid the
contamination.
We inoculated the pre-inoculum of the algae into two different flasks.
Further we kept it on the shaker @161rpm with the proper availability of
the sunlight.
The media with the culture was allowed to grow for the period of 15days .
Once the growth is dense we scaled it up to 500ml flask with the same
parameters.
The OD 0f 0.56 to 0.65 confirms the growth of algae.
Harvesting & Lipid Extraction
This is the very important step in the biodiesel production because it is the process
that help in obtaining the dense lipid content &it has to be done at right time. We
extracted the lipids from the biomass using the soxhlet extraction method.
Methodology
The sample was homogenized and weighed accurately.
Mix the sample with anhydrous sodium sulphate with a 4:1ratio.
Take 150ml of hexane in the erlynmeir flask.
Set up the apparatus.
Start boiling the mixture at the boiling point of hexane and use the boiling
chips.
Finally the excess water is evaporated and the lipid is obtained.
Lipid Analysis
Once the lipid was obtained we used the Folch protocol to estimate the lipid
content.
A 15-ml glass vial containing algal biomass, 2 ml methanol, and 1 ml chloroform
were added and kept for 24 h at 25°C. The mixture was agitated in a vortex for 2
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min. One milliliter of chloroform was again added and the mixture was shaken
vigorously for 1 min. After, 1.8 ml of distilled water was added and the mixture
was mixed in a vortex again for 2 min. The layers were separated by centrifugation
for 10 min at 2,000 rpm. The lower layer was filtered through Whatman No. 1
filter paper into a previously weighed clean vial (W1). Evaporation was carried on
in a water bath and the residue was further dried at 104°C for 30 min. The weight
of the vial was again recorded (W2). Lipid content was calculated by subtracting
W1 from W2,and was expressed as % dcw. At the end of the experiment we got
the lipid content to be 6.3g/250ml which tallies with the standard i.e, 33g/ltr.
Oil Production
Trans-esterification refers to the reaction of an ester group with an alcohol that has
a structure different to that of the original alcohol moiety of the ester, such that a
new ester group is formed in which the original alcohol moiety is exchanged with
that of the reacting alcohol. In the case of the trans-esterification of triglycerides of
fatty acids (vegetable oils) with methanol (classical biodiesel production process),
the three ester groups of a triglyceride molecule in which three fatty acid moieties
are attached to a single alcohol moiety (i.e. that of glycerol) react with three
molecules of methanol to yield three molecules of esters each containing single
fatty acid and methanol moieties and one molecule of glycerol (Scheme 1).
Therefore, the general chemical name of biodiesel produced by the trans-
esterification of vegetable oils is fatty acid methyl esters (i.e. FAME biodiesel).
Methodology
Sodium /potassium methoxide is prepared freshly by pre-determining the
quantity of NaOH/KOH usually 1% of the weight.
The lipid and the alkoxide is mixed in a flask with the continuous stirring at
a temperature of 65-75degree celcius.
After the completion of the reaction it is carefully transferred to a separating
funnel to stand over-night.
Then the oil is drained and collected in flask for FA.
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Nano-Particle Synthesis
Initialy 1M of Zinc chloride solution is prepared
Then 0.4M of NaOH solution is prepared
Next the Zinc chloride solution is poured into the burette and it is added
slowly to the NaOH solution in the beaker
As it is added slowly drop by drop the cloud thick cottony mass is formed
Separate the mass from the solution by simple filtration
Then dry the mass in Hot air owen for half an hour
It produces the white crystals
Then calcinate the crystals at 700 degree for 20minutes thus obtaining the
nano particles
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NANO PARTICLE CHARACTERIZATION
Effect of Catalysts
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Sensitivity Analysis Of Water Washing
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In order to decrease the amount of NaOH and HCl in the product stream, water
washing is used along with adiabatic decantation. To determine the amount of
water to be used, a sensitivity analysis is needed to evaluate the impact of the
amount of water used on the remaining impurities. The result of the sensitivity
analysis is plotted for scenario as shown in Figure. In this figure, it can be seen that
the amount of NaOH and HCl in the biodiesel stream decreases significantly as the
amount of water used in the washing process increases. However, after it reaches
300 mol of water, the catalyst amount removed from the biodiesel stream becomes
less significant. Therefore, 300 mol ofwater is considered to be the practical
amount of waterneeded for the washing process.
ENGINE TESTING
Type TVL vertical 4 stroke cycle, single
cylinder, high speed, CI Engine
Serial Number 234/172
BHP 5.2
RPM 1500
Method of starting Manual crank start
Compression ratio 17.5:1
Coolant Water
Stroke 110mm
Bore 875mm
Governor type Mechanical Centrifugl type
Injection time 19/23/27
Injector 3hole of 0.3mm dia
Injection pressure 230bar/2601
Nozzle opening pressure 200-205bar
In IC engine, the thermal energy is released by burning the fuel in the engine
cylinder. The combustion of fuel in IC engine is quite fast but the time needed to
get a proper air/fuel mixture depends mainly on the nature of fuel and the method
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of its introduction into the combustion chamber. The combustion process in the
cylinder should take as little time as possible with the release of maximum heat
energy during the period of operation. Longer operation results in the formation of
deposits which in combination with other combustion products may cause
excessive wear and corrosion of cylinder, piston and piston rings. The combustion
product should not be toxic when exhausted to the atmosphere. These requirements
can be satisfied using a number of liquid and gaseous fuels. The biodiesel from non
edible sources like Jatropha, Pongamia, Algae etc meets the above engine
performance requirement and therefore can offer perfect viable alternative to diesel
oil.
Test Plan
When this project was begun, the original plan was to be operational mid-way
through the second academic term so that long term reliability testing could be
done. Throughout the term, construction in and around CEME 1115D (the engine
lab) and scheduling difficulties with the MECH 302 engine testing laboratory
prevented operations. The Superflow 901 dynamometer has the ability to measure
many different performance evaluation criteria on an engine. The performance data
can either be read manually from the control console, or with a data acquisition
system and computer. Due to time constraints and problems with the data
acquisition system, readings were taken by hand using the control console.
Measurements taken in this experiment were engine speed, torque output, power
output and airflow. These can all be read off of the control console. Also, average
fuel consumption was measured by weighing the fuel on a digital readout scale
before and after extended tests.
Pre-Test Procedures
Before testing, a variety of checks and tasks must be carried out. The engine
should be inspected visually for any problems, and the dynamometer should be
thoroughly checked for proper operation. Additionally, the engine should be
properly warmed up prior to tests for two reasons.
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First, the engine can be damaged if run under high loads before reaching
proper operating temperature.
Second, torque, power, fuel flow and many other types of readings tend to
fluctuate depending on engine temperature. Once the engine reaches
operating temperature, the readings will be reliable.
Performance Characterization
For any long-term engine testing, it is necessary to evaluate performance
characteristics before testing period to establish a good baseline. Following long
term testing, the performance tests can be carried out again to ascertain whether
there has been a significant degradation in the condition of the engine due to the
use of a different fuel.
The Kubota performance characterization was carried out to simulate actual
operating conditions. This particular engine is designed to run at or near peak RPM
for entire working days under full load. Therefore, performance testing was done at
wide open throttle at a variety of loading conditions. Loading was simulated by
setting the dynamometer to servo-mode on the control panel. The servo function
essentially applies the load required to maintain the engine at the desired speed.
The Kubota will run as low as 800 RPM, but under full throttle operation, the
engine struggles if it is loaded this much. Also, the internal engine speed governor
is set around 3100 RPM, at which point the fuel supply is limited. As a result, at
the governed speed, the engine torque output drops significantly and the engine
will not rev any higher. The speed was varied in 100 – 200 RPM increments from
1600 to 3100 then back down to 1600 using the servo control dial. The speed was
varied by ramping up and then back down again to eliminate hysteresis in the
measurements. Torque, power, and airflow were recorded for each speed
increment. Graphs in the following section show the results of the performance
characterization tests for the three different fuels.
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Fuel Consumption Measurements
These tests are done to evaluate any differences in fuel consumption when the
engine is running on the three different fuels. The data can also be used to evaluate
the thermal efficiencies of the engine when running on each type of fuel. The
consumption tests were done by filling the fuel tank with the test fuel then
weighing it with a digital scale accurate to 1 gram. The engine was then started and
run at wide open throttle and loaded to 2800 RPM using the servo function. It was
run for 40-60 minutes while recording torque, power, airflow, ambient temperature
in the lab and relative humidity in the lab every 10 minutes. Once the engine was
stopped, the fuel reservoir was weighed again to determine the total mass of fuel
consumed in the test. The data is used to determine brake specific fuel
consumption and thermal efficiency.
Reliability Testing
Reliability testing with B20 fuel is the primary objective in this experiment. Since
there was not sufficient time to carry out extended tests, this will have to be done
in the future. In total, about 7 hours of testing was done using B20 fuel. Additional
tests with regular diesel and neat biodiesel increased the total running time of the
engine to almost 10 hours. This does not meet the original project objective of
200+ hours of B20 testing, but is a good start for future work. The reliability
testing was done under the same conditions as the fuel consumption tests. The fuel
injector in cylinder #1 was inspected before and after the test work in order to
evaluate whether any deposits had accumulated.
Post-test Procedures
After full-load testing, the engine should be idled-down for at least 3 minutes in
order to stabilize the internal engine temperature. This can not always be done
when testing fuel consumption because the dynamometer measurements fluctuate
at low RPM. However, it should be done whenever possible to prolong the life of
the engine.
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Data Acquisition
The performance characteristics were read manually from the dynamometer
console, which proved time consuming. Automatic data acquisition would greatly
improve the speed and accuracy of tests. Measurement of fuel flow rate is
especially important. The flow rates taken during these tests involved weighing the
fuel reservoir before and after a constant speed run. This method is time
consuming and prone to error. It also prevents flow measurement during
performance tests where the operation conditions are changing in time. In the
future, it would be beneficial to acquire a signal from the scale and record the mass
over time. This would allow the fuel flow rate to be easily synchronized with the
instantaneous operating conditions. Exhaust gas temperature acquisition is also
desirable. As discussed in the following section, an in-cylinder pressure transducer
would allow measurement of the ignition advance and peak cylinder pressure. It is
important to determine how these values change with fuel properties and exhaust
emissions. A shaft position encoder will also be required for this measurement.
Engine oil dilution
Studies have noted that engine lubricating oil tends to become diluted with fuel
more quickly when running biodiesel instead of diesel. Most manufacturers
recommend doubling the oil change frequency when using biodiesel. It was
planned to periodically test the viscosity of the engine oil over the course extended
operation. Again, time constraints prevented these long runtimes, so this should be
done in future tests. It has been suggested that the reason for this is related to the
larger fuel droplet size and incomplete burning of biodiesel. Remaining fuel may
find its way past the piston rings and into the oil pan. Biodiesel is also a better
solvent than diesel, so this may also play a role in the oil dilution rate. Regardless
of the cause, the dilution rate should be quantified.
Following conclusions are made from the results and observations.
» The bio-diesel is more eco friendly compare to Diesel.
» Bio-diesel is the substitue of Diesel
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» Without any modification in Diesel Engine the Bio-diesel can be used as
fuel.
» The wear and tear on components is under limit.
» Bio-diesel is more suitable fuel for slow speed Diesel Engine compare to
high-speed Diesel Engine.
» Exhaust temperature is higher compare to diesel operation.
» Lubricant oil get early deteriorate compare to diesel due to the glycerin as
composition in bio-diesel.
» Specific fuel consumption is Higher (8 to 15%) comparing to diesel without
modification in Diesel Engine.
» To have more details study it is suggested to undergo the test as per IS-
10000 & 10001 of 1981/11700 of 1985 which consist of 512 hours test (32
cycle-16 hours per day).
» Bio-diesel can be better fuel for future, which is made from agriculture
product (Renewable Energy).
» Bio-Oil is also one of the alternative fuel can be use along with Diesel up to
20% without refines.
Results and comparison
Here we compare the bio-diesel characteristics data with the ASTM standards and
normal diesel standards.
Parameters ASTM standards Diesel Algal bio-diesel
Density 0.86-0.91g/cm3 0.85g/cm3 0.889g/cm3
Viscosity 1.9-6mm2/sec 2.6mm2/sec 4.97mm2/sec
pH value 4.6-6.4 - 5.6
Acid value 2.8-9.16mg.KoH/g 0.4mg.KoH/g 3.97mg.KoH/g
Saponification
value
125-
244.8mg.KoH/g
- 189.3mg.KoH/g
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Flash point 127-221°c 75-110°c 179°c
Fire point >=150°c - 201°c
Molecular weight - - 933.45g
Iodine value <=125mg - 120mg
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ENGINE TESTING RESULTS
Parameters Diesel B20 B40
BP 5.15kw 4.97kw 4.9kw
Torque 9425NM 3629.8NM 7259.4NM
Fuel consumption 0.000335kg/s 0.0003426kg/s 0.0004852
Kg/s
BTE 38.5% 32.47% 28.58%
Volumetric
Efficiency
88% 78% 80%
IP 8.5kw 7.57kw 7.7kw
FP 3.2kw 2.6kw 2.8ke
Mechanical
Efficiency
77.5%
65.7%
63.6%
HC 29.92ppm 21.47ppm 19.8ppm
CO 0.119% 0.102% 0.09%
CO2 4.18% 4.12% 3.79%
NOx 22.5ppm 32.56ppm 39.8ppm
BSFC 0.286 0.328 0.356
CALCULATIONS
1. Brake Power=2πNT/60000
2. Torque=FxRadius
3. Fuel Consumption=0.025xConstant(0.889)/Time for 25cc fuel
4. Brake Thermal Efficiency=BP/(mfxCV)
5. Volumetric Efficiency=Va/Vs
6. Vs=(π/r)xstrokexBorexRadius
7. Va=Cdx
8. IP=pmLAN/60
9. Mech=Bp/IP
10. FP=IP-BP
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Engine Testing Online Software Data Aquisition-80% Load
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Engine Testing Online Software Data Aquisition-100% Load
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Conclusion
From the comparison we can say that all the test done and results obtained are in
the range defined by the ASTM standards. Hence algal bio-diesel can be
considered as a fuel and can be used in automobiles with minor
modifications.Current efforts and business investment are driving attention and
marketing efforts on the promises of producing algal biodiesel and superior
production systems. A large number of companies are claiming that they are at the
forefront of the technology and will be producing algal biodiesel economically
within the next few years. However most of these companies have limited
technical expertise and few have actually made biodiesel from algae. Producing
algal biodiesel requires large-scale cultivation and harvesting systems, with the
challenging of reducing the cost per unit area. At a large scale, the algal growth
conditions need to be carefully controlled and optimum nurturing environment
have to be provided. Such processes are most economical when combined with
sequestration of CO2 from flue gas emissions, with wastewater remediation
processes, and/or with the extraction of high value compounds for application in
other process industries. Current limitations to a more widespread utilization of
this feedstock for biodiesel production concern the optimization of the microalgae
harvesting, oil extraction processes, and supply of CO2 for a high efficiency of
microalgae production. Also, light, nutrients, temperature, turbulence, CO2 and O2
levels need to be adjusted carefully to provide optimum conditions for oil content
and biomass yield. It is therefore clear that a considerable investment in
technological development and technical expertise is still needed before algal
biodiesel is economically viable and can become a reality. This should be
accomplished together with strategic planning and political and economic support.
Further efforts on microalgae production should concentrate in reducing costs in
small-scale and large-scale systems. This can be achieved for example by using
cheap sources of CO2 for culture enrichment (e.g. from a flue gas), use of nutrient-
rich wastewaters, or inexpensive fertilizers, use of cheaper design culture systems
with automated process control and with fewer manual labor, use of greenhouses
and heated effluents to increase algal yields. Apart from saving costs of raw-
materials (nutrients and fresh water use), these measures will help to reduce GHG
emissions,waste amount, and the feed cost by using of nitrogen fertilizers.
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Also, will raise the availability of microalgae biomass for different applications
(e.g. food, agriculture, medicine, and biofuels, among others) and will contribute to
the sustainability and market competitiveness of the microalgae industry.
Accomplished work
Successfully completed the characterization of the biodiesel based on ASTM
Standards
Over came the difficulty of the corrosion by Zinc oxide nano particles
Large scale production of bio diesel done successfully
Filter clogging effect is normal and often due to fuel shifting and when it
gets persisted automatically the problem disappears
Engine testing
Human Resource
Initially when we came to know about the CTE we were really excited to be a part
this event and now we are really proud of being a part of the CTE team. The team
building was the difficult task because to match the people with similar mind
frequency is a bitter job. But as the work got progressed even we adapted to the
changing environment and got exposed to the huge learning atmosphere and as a
engineering students we got to learn about the market search, segment and
managing skills. Right now there is no team conflicts and we hope to manage the
same throughout the entire phase of the project and again thanks to CTE for this
wonderful platform.
FUTURE WORK
We want to blend the algae oil with the ethanol to make it as the power diesel
called “ALGAENOL” to make it a better fuel and to increase all its efficiency and
performance so that it get converted to 4th
generation fuel.
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Photos
Scenedesmus algal culture
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Nano-Chloropsis Occulatta
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Algal culture grown at shake flask level
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Soxhlet Extraction
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ALGAL BIO-DIESEL
Team with product
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Guide with product
References
1. . Halim R, Michael KD, Paul AW (2012) Extraction of Oil from Microalgae
for Biodiesel Production: A Review. Biotechnol Adv 30: 709-732.
2. Vlysidis A, Michael B, Webb C, Theodoropoulos C (2011) A Techno-
Economic Analysis of Biodiesel Biorefineries: Assessment of Integrated
Designs for the Co-Production of Fuels and Chemicals. Energy 36: 4671-
4683.
3. . Liu J, Huang J, Fan KW, Jiang Y et al. (2010) Production Potential of
Chlorella Zofingienesis as a Feedstock for Biodiesel. Bioresource Technol
101: 8658–8663.
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4. . Demirbas MF (2011) Biofuels From Algae for Sustainable Development.
Appl Energ, 88: 3473–3480.
5. . Janaun J, Ellis N (2010) Perspectives on Biodiesel as a Sustainable Fuel.
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The Ideal Vegetable Oil-Based Biodiesel Composition: a Review of Social,
Economical and Technical Implications. Energy Fuels 23: 25–41.
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ignition engine characteristics using methyl and ethyl esters of Karanja oil,
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8. J .Siddarth, “Performance Evaluation Of IC Engine Using Biodiesel from
different fuel sources “ M.Tech Dessertation June 2008 ,IIT Roorkee
9. G.Dwivedi “Performance Evaluation of DieselEngine Using Biodiesel from
Karanja Oil “M.Tech Dessertation June 2011,IITRoorkee
10. Gaurav Dwivedi, M.P.Sharma, Siddarth Jain, “Impact of biodiesel and its
blends with diesel and methanol on engine performance”, International
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11. Gaurav Dwivedi, M.P.Sharma, Siddarth Jain,” Pongamia as a source of
Biodiesel in India-A review”, Smart grid and Renewable Energy, Paper
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