Waste Cooked Oil as an Alternative Feed
Stock for Bio-Diesel Production in Indian Railways.
Arvind Lal1, A. Kumar2, A.K. Gupta3
and N.K. Yadav4.
1Indian Railways Institute of Mechanical
and Electrical Engineering, (IRIMEE) Jamalpur. Bihar - 811214
2 Department of Mechanical Engineering,
BIT,Mesra Ranchi. Jharkhand
3 University Department of
Chemistry, L. N. M. University, Darbhanga, Bihar
4 P. G. Department of Chemistry,
T. M. Bhagalpur University, Bhagalpur, Bihar
*Corresponding Author E-mail: lalarvind2@gmail.com
ABSTRACT:
Knowing the
enormous potentialities of bio-diesels, Indian Railways has taken up challenge
to produce it from plantation of Bio-fuel plants (Jatropha) on a large scale in
the vast vacant lands throughout the country including the track sides, and
decided to run its Diesel locomotives, road vehicles and even generator sets on
it to minimise the air pollution extent in the IR premises. But due to
non-availability of regular feedstock (Non-edible oils), it is difficult to
continue the same. In this work ,bio-diesel was prepared through the
transesterification from waste cooked oils(WCO), collected from Star
hotels in and around new Delhi and from the canteen of Queen’s Road Hostel,
E. Railway Jamalpur. Methyl alcohol with KOH as a catalyst was used for the
process. The best result was found at the temperature of 650C with a
reaction time of 1 hour. The biodiesel was characterized by its physical and
fuel properties including viscosity, flash point, carbon residue, water and
sediments content according to ASTM Standards and found to be comparable as per
IS: 15607/05.Production of biodiesel from waste cooked oils for the diesel
substitute is particularly important because of the decreasing trend of the
economical oil reserves, environmental problems caused due to fossil fuel use
and the high price of petroleum products in the international markets.
KEYWORDS: IR (Indian Railways), HSD oil (High speed diesel), waste cooked
oil (WCO), Transesterification, free fatty acid (FFA) etc.
1. INTRODUCTION:
IR (Indian Railways) has one of the largest
and busiest rail networks in the world, transporting over 18 million passengers
and more than 2 million tonnes of freight daily[1]. Traditionally,
IR has been accorded priority for supply of energy for traction purpose. But
due to power cuts, IR has an adverse effect on the overall performance of the
entire system. So, IR has taken a decision to adopt alternative source of
energy (BIO-DIESEL) to meet its fuel requirements as well as to overcome the
air pollution problems. Biodiesel fuel has become more attractive because of
its environmental benefits [2], due to the fact that plants and
vegetable oils are renewable biomass source.
Compared to petroleum diesel, biodiesel has
lower emission of pollutants, it is biodegradable and enhance the engine
lubricity and contributes to sustainability[3,4] Biodiesel has a
higher cetane number than diesel fuel, no aromatics, no sulphur, and contains
10-11% oxygen by weight[5]. Hence a considerable work has been done
by Indian Railways at Research Design and Standards Organization (RDSO) and
IRIMEE to assess the suitability of Bio-diesel for the Indian Railways
application as an alternative to power the Diesel locomotives as well as road
vehicles.[6]. The price of edible plant and vegetable oils is
usually higher than petrodiesel. The use of waste cooked oil as biodiesel feed
stock in Indian Railways reduces the cost of biodiesel production, since the
feedstock cost constitutes approximately 70-95% of the overall cost of the
biodiesel production[7]. Hence, the use of waste cooked oils and
non-edible oils should be given higher priority over the other oils as
biodiesel feedstock.
The objective of the paper is both to
develop self-sufficiency as well as to develop an energy source that is
non-polluting, environment friendly and cost effective. The properties of
Biodiesel are very similar to those of existing diesel (HSD oils IS: 1460/2005)
and it can be blended in various proportion to the diesel.
1.1
Potential
of waste cooked oil as a feed stock for bio-diesel source.
Huge quantities of waste cooked oil (WCO)
and animal fats are available throughout the world, especially in the developed
countries as pointed out by Arjun B. Chhetri[8,9] as mentioned in the
table No-1. Though some of this waste oil is used for the soap industry, but
large amounts of waste cooked oils are illegally dumped into rivers and
landfills, causing environmental pollution. Hence the use of WCO to produce
biodiesel offers a significant advantage, due to the reduction in environmental
pollution. Klass[10] along other researchers pointed out that HSD
oil is also the major source of the emission of NOx, SOx, CO, particulate
matters and volatile organic compounds (VOCs).Emission of such pollutants not
only has negative impacts on the global environment but also has severe
impacts on human health due to their persistence in the environment. Hence
WCO, which is otherwise wasted, would be one of the most economical choices to
produce biodiesel.
1.2 HSD oil consumption and uses of
biodiesel in IR.
Approximately two billion liters of diesel
fuel are consumed annually by the 4,000 freight and passenger locomotives in
the Indian railway fleet. The prime mover in all but a few of these locomotives
is the medium-speed diesel engine, having power levels ranging up to 4000
horsepower. The expenditure of Indian Railways on diesel fuel is Rs 4400
crores. Diesel fuel is approximately 18 percent of railways’ total operating
expenses.[11]. A blend of B20 (20% biodiesel and 80% petro diesel)
has been found most suitable to IR and climatic conditions. A B20 blends
equates to an overall annual railway market potential of 400 million liters of
neat biodiesel.[11]. By the year, IR has planted more than 12 millions
of Jatropha plants on the vacant lands especially along the track sides and the
figures are increasing by leaps and bounds. Already 4 (four) esterification
plants for manufacturing of Biodiesel have been set up in different locations
and some more are in pipeline [11]. But due to shortage of these
feed stocks, waste vegetable or cooked oil has taken as a feedstock for making
bio-diesel in IR application.
2. MATERIALS AND METHODS:
2.1 MATERIALS AND OPTIMISATION OF BIODIESEL
PRODUCTION FROM WCO.
Waste Vegetable oil or cooked oil is
collected from the star hotels in and around Delhi and stored at Sakurbasti
Diesel shed as a feedstock, in the Nothern Railway applications. Some used
cooked oils are also collected from the canteen of Queens Road hostel of Eastern
Railways, Jamalpur (Bihar) for the experiment.
It is well recognized that the waste cooked
oil is a result of the frying temperature, length of the use as well as the
material used for the frying. The oil used for the cooking was not single oil but
mostly refined soybeans and other blended ones. The used oil sample was taken
from the frying potatoes, fish, chickens and other vegetable based food items.
Before going to the actual transesterification, the oil was first conditioned
to remove sediments and moisture etc. The oil sample was heated in a beaker to
1100C to evaporate off the water and after cooling, was filtered
using a cloth (75 micron) to separate any particles. The percentage of free
fatty acid (FFA) was then measured from titration method. (N/10NaOH solution
using phenophthein as indicator) and accordingly, the next steps were taken.[12]
If the FFA is less than 4 to 5, single step process is sufficient but if it is
more than 5 (Five) then acid treatment process is to be done to reduce it below
Four (4).In this case FFA was found to be less than four hence ,single step
process was used. From the titration, the total amount of catalyst per liter
of waste cooked oil was determined to be 14 grams of KOH per liter of waste
cooked oil. This amount was confirmed to be correct by actual experiments.
First of all a mixture of 180 ml of
methanol and 14 gram of KOH (both L.R grade from MERCK) was prepared and it was
then poured into 1 liter of oil placed in the reaction vessel. The oil was
kept in a thermostat at 65±5°C with a stirring of 250-300 rpm. On addition of
the alcohol and base mixture the stirring was increased to around 600 rpm, for
20 to 30 minutes for getting better collision of reactants.
The reaction mixture was then allowed to settle
in a separating funnel for about 12 hours. When the two phases of glycerol and
Biodiesel became clearly distinct, they were separated out.
The upper phase of Bio-diesel was washed 3
to 4 times with distilled water to remove excess of unreacted oil, catalyst and
methanol until it become completely translucent and was finally dried at
100±10°C in oven to remove the water or moisture.
The best result with more yield ( 90%) and
minimum time ( 1 hour) was obtained with oil: alcohol: KOH ratio of 1 liter:
180.43 ml: 14 gram as mention in table no-2. The so recovered biodiesel was
then subjected to various tests as mention in table - 3 at Diesel Shed
Laboratory, Eastern Railways as per IS: 1460/05 or IS: 15607 for comparison.
Table No-1.Feedstock of waste cooking oil
|
Sl.
No
|
Country
|
Availability
|
|
1
|
USA
|
100millions
gallons/day
|
|
2
|
Canada
|
135,000tons/year.
|
|
3
|
E.U.
|
700,000-1,000,000
tons/year
|
|
4.
|
U.K
|
200,000
tons/year.
|
|
5
|
India
|
Figure
not available.
|
2.2 BIO-DIESEL PROCESSING UNITS AND
TRANSESTERIFICATION REACTION:-
One pilot plant of capacity 5(five) litre
made of glass having three separators, reaction vessel, alcohol recovery and
auto temperature controlling device was set up at IRIMEE, Jamalpur. More than
20 batches of biodiesel (3.5 Litre) were made and it was used in IRIMEE generator
as B10 without any adverse effect.
Biodiesel, fatty acid of methyl esters used,
is obtained by the alkali- catalyzed transesterification reaction of the waste
or cooked vegetable oils with alcohols.
Where, R’, R’’ and R’’’ are the
different types of fatty acid chains associated with the oil which are largely
palmitic, stearic, oleic and linoleic acids ( from 16 to 18 carbon chain). For
shifting the equilibrium to the right side the molar concentration ratios of
alcohol: oil is kept more than 3:1.
3. RESULTS AND DISCUSSION:
3.1 Fuel characterization:
The sample was tested to determine the fuel
characteristics according to ASTM biodiesel fuel quality assurance standard
test. Table -3 shows the summary of the test method used, the standard limit as
recommended by IS: 15607/05.
(1) Though the Biodiesel are to be tested
for impurities associated with it coming through the transestrification
process, yet no sedimentation no. water content and clear appearance and other physical
properties mentioned in the chart coming within the prescribed limit tell
much about their purity.
(2) Biodiesel and its blends are
susceptible to growing microbes when water is present in them. The solvency
property of Biodiesel can cause microbial slime to detach and clog fuel
filters. In our findings all the Biodiesel are completely free from water
content.
(3) The yield of Biodiesel obtained in
this method is about 90%. The least yield from waste cooked oil indicates a
higher percentage of FFA in the oil and a percentage of it going under
saponification.
(4) The acid value can be used to guide
in quality control of fuels. Acid value of WCO Biodiesel as obtained was found
well within the standard of 0.5, which shows that FFA coming from the mother
oil is minimum and would not come in the way of performance of IC Engine.
(5) The viscosity of liquid is an
important characteristic as it determines the ease of flow through pipeline,
injector nozzle and orifices and formation of fuel in the cylinder. The
kinematic viscosity of Biodiesel and its blends were within the prescribed
standard limit.
(6) Specific gravity specification is
needed in India to check for any contamination or adulteration. It was
found within the prescribed limit for all the case.
(7) Flash point measures the tendency of
the sample to form a flammability mixture with air and as per Indian standard
it must be of minimum 120°C. In this case, this point was 162oC
which is not only beyond the prescribed limit and above the HSD but it will
also be easier for storage for their less inflammability.
(8) Carbon residue of the fuel is
indicative of carbon depositing tendency of fuel. In case of Biodiesel, it
shows a high correlation with presence of free fatty acids, glycerides, soaps, polymers,
higher unsaturated fatty acids and inorganic impurities. Carbon residue for WCO
biodiesel was found higher than the prescribed limit. It shows the
presence of any of the above mentioned substances.
9. The calorific value of WCO biodiesel was found to be 38.60 MJ/kg and is less
than the calorific value of diesel (44.0 MJ/kg) but greater than that of pure
oil. As the percentage of bio-diesel in the blends increased, the calorific
value decreased.
(10) Rinsed water of Biodiesel may be
utilized as irrigation purposes for plants after treatment of water as per norms of Central Pollution control
Board (CPCB). (BOD 6.6 mg/l, TDS-453mg/l, pH 9.3).
4. CONCLUSION:
From the results and discussions it can
safely be said that waste cooked oil can be an important source for biodiesel
production. WCO biodiesel and its blends may prove suitable for Indian Railways
application as there is large quantity of waste cooked oil available. The star
hotels supply these oil free of cost to Indian Railways specially at sakurbasti
diesel shed to maintain its own reputation and at the same time it also helps
to improve the biodiesel economics in Indian railways.
5. ACKNOWLEDGEMENT:
The author would like to acknowledge
Director, IRIMEE to grant for conducting research at IRIMEE, Jamalpur and also
thankful to Incharge of Diesel shed Laboratory, Eastern Railway Jamalpur for
providing test reports in due time.
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