DESIGN OF ESSENTIAL OIL
EXTRACTION PLANT AND
CONDUCT FEASIBILITY FOR ITS
OPERATION
Supervisor:
Members:
Dr. Bhupesh Adhikari
Lama(41068)
Group
Nurbu
Santosh Nepal(41069)
Sujan Shrestha(41088)
Acknowledgement
Dr. Bhupesh Adhikari (Supervisor)
[Link] Shrivastav(Ministry
of soil and forest conservation)
[Link] Maharjan(General
Mechanical Workshop)
ANSAB
Trade and Export Promotion Centre
Khaptar Aroma [Link]
Contents
Introduction
Objective
Literature survey
Existing plants
Limitations of existing plants
Site visits on other organization
Raw materials
Technology
Equipments of steam distillation
Selection of technology
Market survey
Work completed
Work remaining
Materials and methodology
Conclusion
Gantt Chart
References
Introduction
Volatile oils -distillation process
Used in medicinal, perfumers and
cosmetics
Steam distillation -effective extraction
Small scale -not profitable at present price
of raw material
High scale- financially difficult
Medium size -favorable for Nepal
increase public demand - low priced
product
Objective
To design the essential oil extraction
plant.
To conduct out the feasibility of its
operation in Nepal.
To estimate the budget on
constructing a plant.
Literature survey
The chemistry of essential oil
Treatment of plant material before
distillation
[Link] of the plant
2. Storage of the plant material:
3. Loss of essential oil in the plant material
prior to distillation
4. Change in the properties of essential oils
during plant drying.
Theories of distillation- methods and types
Existing plants
Herbs production and processing
company limited(HPPCL)/(Jadibuti)
Processing lemongrass, citronella, palmarosa,
mentha, chamomile, sayapatri.
steam distillation unit
Batch production type
International market based company
Production based on market demand
Shipping done in a epoxy-coated big metal
container or aluminium containers
Distillation unit of
HPPCL
Vessel
Capacity -1500 liters
Type cylindrical (vertical) field
type
Size-dia.1.2m 1.4m height
Condenser
Capacity - 3 sq.m
Type
- vertical shell and
tube type
Receiver
Capacity - 50 liters
Type - cylindrical and top
conical
Size- diameter 300 mm* 600
mm
Metal - 2 mm thick SS 304
Boiler
Capacity - 250 kg/h
Type
- wood fired
Steam pressure - up to 2
Kg/cm2
Distillation unit
Khaptar Aroma, Godavari
Distillation- 4-5hrs
operated
Processes-Jatamasi
plant.
Residue removed
manually
Residue Export to
India
rate -Rs.250/kg
used for making
incense stick
Drying of Jatamasi before processing
Distillation unit
Vessels (3units of
total 550kg capacity)
Vessel 1-150kg
Vessel 2-100kg
Vessel 3-300kg
Condenser
Type
- vertical shell
and tube type
Boiler
Wood fired (uses firewood
of 2500kg/day)
Located at a distance 15
meter apart from other
units
Oil separator
Water tanks ([Link]
1000ltr capacity each)
Distillation unit of Khaptar Aroma
Utilization and Pilot
Section, Godavari
Distillation and extraction unit
available
small manufacturers bring the raw
material and process
raw materials- not specific
Distillation
unit
Vessel
Capacity-1500litres
Materials-Stainless steel2 inch thickness
Indian unit
Condenser
Spiral type
Boiler
Type Oil-fired boiler
Units -2
German boiler of
capacity 1500kg/hr
Indian boiler of 300 kg/hr
Kerosene oils (use
20lt/hr)
Vessel in utilization and Pilot section
General Mechanical
Workshop (Gwarkho)
Fabricator of distillation
unit
Has send many distillation
unit whole over Nepal
Also works as a
manufacturer of essential
oil in small scale.
Vessel-capacity 1000lt
Condenser- shell and tube
receiver -8 ltr. capacity
fire tube boiler
Natural Flowers [Link].
Plant location: Basamadi-5, Hetauda
extraction unit
Vessel- 2000lt
processes medicinal herbs only
Sell to local and international market
Limitations of existing
plants
retort height 3-4 times diameter
slow oil recovery
steam flow rates - experience based
More steam produced resulting more
fuel consumption
Optimum capacity boiler not choosen
Site visits on other
organaisation
National Productivity and Economic
Development Centre Limited (Balaju) feasibility study
information regarding the previous works carried out
Trade and Export Promotion
Centre(Pulchowk) statistical data about the import and export
Asia Network for sustainable Agriculture
And Bioresources (ANSAB,Bhemsengola)
Study and availability of herbs
promotion for essential oil
Raw materials
Herbal plants
Cultivated in Mid hilly and Terai regions of
central [Link]
Economic importance
Pamaroja,Lemongrass,Citronela,Mentha,Fr
ench
basil,Chamomaile,Syapatri,Indrayani
Technology
Types of Technology
Distillation
Extraction
Soxhlet Extraction
Water
Distillation
Water and Steam Distillation
Steam
Distillatio
n
Percolation
Extraction
Equipments in Steam
Distillation unit
The retort
The condenser
The receiver
Boiler
Units components
Retort
Condenser
Oil separator
Selection of technology
steam distillation
high rate of distillation
temperature can be controlled
Estimated specifications of equipments
Vessels
Total capacity 2000litres of 1 vessels
material-stainless steel304
Contd..
Condenser
vertical condenser-shell and tube type,
counterflow.
GI pipe inside
material stainless steel 304
Oil separator
14 litres capacity
Material-Aluminum
Boiler fire tube- 300kw (low cost, availability).
Proposed schematic flow
diagram of distillation unit
Proposed plant layout
Market
International markets-export and import
to various countries
Domestic market - very meager
used by: ayurvedic hospitals
perfume company
cosmetic items
Mostly produced essential oils - Lemon
Grass, Citronella, Palmarosa, Sayapatri,
Mentha, Jatamasi, Rose, Dhasingre,
Chidepari plants.
contd..
Name of plant
Oil production (in Kg.) per Cost of production (in Rs.) per Cost of oil (in Rs.) per Kg.
hectare
Hectare
Lemon Grass (Cymbopogon flexuosus Steud)
70
20000
1500
Citronella (Cymbopogon winterianus Jowitt)
100
20000
950
Palmarosa (Cymbopogon martini [Link])
70
20000
1500
Mentha (Mentha arvensis L.)
100
25000
1550
Chamomile (Matricaria Chamomilla L.)
60
35000
35000
Sayapatri (Tagetes glandulifera Schrank)
25
20000
1500
Source* HPPCL,Jadibuti Kheti Pustika, 2059 B.S.
Import and export data
Source: Trade and promotion Centre, Nepal
Work completed
Theoretical literature review
Theories of distillation- methods and types
Chemistry of essential oil
Raw materials
Methods of treatment of plant before processing
Market survey
Cost and availability of raw materials
Site visits on
Herbs Production and Processing Company Limited
Utilization and Pilot Section, Godavari
General Mechanical Workshop (Gwarkho)
Khaptar Aroma, Godavari
Natural Flowers [Link].
Study and analysis of distillation unit installed in above sites
Contd..
Comparison of the different companies
Financial Structure of different materials and
equipment
Engineering know how for design phase
Schematic of the whole distillation unit
Foundation for the design phase
Work Remaining
Site visit - if required
Retort
capacity, material to be used in fabricating,
welding type, welding stitch, material thickness
Condenser
pipe inside the condenser and its material, no. of
passes
Oil separator
capacity, diameter of its mounting, material to be
used
Boiler
capacity, flow rate, temperature and pressure to
be maintained, material for fabrication or to be
imported
Contd..
Schematic diagram
pump capacity, steam trap type, control valve, water regulating
valve, water tank capacity, temperature of water at tank
Detail dimensions, Autocad drawings
Economic analysis
visits to 3-4 companies for the real cost of different
materials
Total cost of the plant setup
initial cost, operating cost, cost of civil construction and
infrastructure
the rate of return, breakeven point, profitability ratio
Materials and methodology
Selection of the project
Literature survey
Engineering Know How
Detail Design
Feasibility for operation
Engineering Economy
Gantt Chart
No.
Activity
1.
Selection of the project
2.
Literature survey
3.
Engineering know how
4.
Detail Design
5.
Feasibility for operation
6.
Engineering economy
7.
Final report
Total time (days)
Work Accomplished
Work Remaining
Sep
Oct
Nov
Dec
Feb
March
April
May
June
Estimated Days
32
Conclusion
on the way to successful
accomplishment of the project
progressing to meet its objective
the overall achievement - basic layout,
the theoretical literature surveys
relevant to the project and engineering
knowhow
foundation for further progress
project will be completed in time.
References
Committee, Nepal National SCAMAP. Essential Oils '89.
Kathmandu,Nepal: Bahukendra Offset Press, 1989.
Gurung, Khilendra. Essential Oils in Nepal: A Practical Guide
to Essential Oils and Aromatherapy. Kathmandu,Nepal:
Himalayan Bio Trade Private Limited (HBTL), 2009.
Guenther, Ernest. The Essential Oils . Vol. 1. Florida: Krieger
Publishing Company, 1972. 6 vols.
Guenther, Ernest. The Essential Oils . Vol. 3. Florida: Krieger
Publishing Company, 1972. 6 vols.
HPPCL. Jadibuti Kheti Pustika. Kathmandu: Herbs Production
And Processing Co. LTD., 2059 B.S.
Shakya, Mech. Er. Upendra Man. Personal communication
regarding Essential oil plant 8 September 2010.
Shriwastav, Sr. Scientific officer Dharmatmalal. Personal
communication regarding Essential oil plant Kathmandu, 16
September 2010.
Contd.
Giri, Ramesh. Personal communication regarding production cost Kathmandu,
10 November 2010.
Steam Distillation Process - Technical Review. Downloaded from:
[Link] [19 September, 2010]
[Link] [19 September, 2010]
[Link] [19 September, 2010]
Centre, Trade and Export Promotion. A Glimpse of Nepal's Foreign Trade,
Statistical Presentation-2009/10. Lalitpur,Nepal: G.M Printing Press, 2010.
Nepal Foreign Trade Statistics. Vol. 1. Pulchowk,Lalitpur: G.M Printing Press,
Kathmandu, F.Y2009/10.
Joshi, Bhawani Bhakta and Binod Bahadur Thapa. A Ginger Oil Distillation Plant
at Nepalgunj. Industrial Services Centre, 1979.
Hardware, Rajesh. Personal communication regarding material cost
Teku,Kathmandu, 11 January 2011
Acharya, Deepa (Khaptar aroma). Personal communication regarding distillation
unit 12 November 2010.
Alam, Asst. Scientific Officer Sajjad. Personal communication regarding
distillation unit 25 November 2010.
Maharjan, Kancha. Personal communication regarding fabrication 25 November
2010.
THANK YOU