Design and simulation of the biodiesel process plant for sustainable fuel production

The biodiesel production process is extensively studied in the literature, focusing on mechanisms, modeling, and economic aspects, yet plant design and fluid flow losses remain underexplored areas. The study addressed this gap by designing a biodiesel production plant, analyzing flow losses, and developing a pipe network and suitable pump models. In this study, an integration of biodiesel production plant design and simulation of continuous production of Calophyllum inophyllum biodiesel was investigated. Biodiesel production encompasses complex stages that involve systematic planning and system design. The goal of the plant design is to reduce the losses that occur during the conversion process, which can reduce the capital cost of the plant. A few assumptions were made when selecting biodiesel plant materials, such as pipes, pumps, fittings, and bends. These assumptions were based on considerations of the biodiesel fluid properties and pressure requirements. On the other hand, Aspen Plus was used to simulate the biodiesel production process. Calophyllum inophyllum was considered oil as the biodiesel feedstock and was inputted to the Aspen Plus as triglyceride composition. The simulation was carried out with rigorous kinetic reactions using the Non-Random Two-Liquid (NRTL) method to predict the liquid equilibrium in the reactor. Results revealed that the designed steel pipe meets safety requirements with a bursting pressure of 49.68MPa, capable of withstanding the maximum pressure of 4 bar and turbulent flow conditions. Additionally, the selected pump satisfies the required head and flow rate, ensuring efficient fluid movement. Moreover, simulation results closely matched experimental data, and 88% of biodiesel yield was recorded.