Production of Sesame Oil CEAC REVIEW Group 20 Golden Oil

Equipment Design/Cost Emma Huynh Preston Ji Charlotte Ntim Maame Sarpong Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Outline A. Team members B. Summary C. Equipment design D. Cost and Finance E. Design norms F. Progress/Obstacles

Inspiration Team members Project Summary Design Decisions Design Norms A country in central Africa Gained independence in 2011 from Sudan Team members Project Summary Design Decisions Equipment DesignCost Design Norms Progress Obstacles

Equipment Design/Cost Golden Oil Project Produce sesame oil from sesame seed Produce via mechanical pressing following by solvent extraction Project scale: 10,750 tons/year, which is 1% of worldwide sesame oil production Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Why Sesame? Highest oil content (50 wt%) Survivor crop - grows in drought, heat, excessive rain Contains linoleic acid, stearic acid, palmitic acid, etc. Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Why Chemical Extraction? Mechanical process: “Squeezing” the oil out and remove 50 ~ 90% of the oil (depending on particle size) Chemical process: Extract (leach) with solvent (n-hexane) and remove 98 ~ 99% of the oil with minimal health adverse Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Source of Data Have difficulty to find data/info in South Sudan Data source is available in America Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Process Flow Diagram 1. Grinder 2. Leaching Tank 3. Hexane-Oil Separation Design Decision Equipment Design/Cost Design Norms

Equipment Design/Cost Operating Conditions Temperature: 50 ~ 150 ℃ Around the normal boiling point of hexane (69 ℃) Pressure: 0.2 ~1 atm Increase volatility of hexane for better separation Reduce the risk of a hexane (flammable) leak Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Harvest and Storage Assume 1 harvest per year 8,000 hours of operation per year Assume our products can be stored in bins/tanks large enough to hold 7 days of continuous operation Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Choice of Solvent We choose n-hexane as our solvent Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Material Balance Assume 49% of the oil is extracted via mechanical pressing and 50 % via chemical extraction Total of 99% of the oil is obtained Recycle ratio of hexane 20:1 Solvent to seed ratio 1.25:1 Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Grinder Solid processing → no simulation available Heat of friction: A separate roaster may not be necessary Design Decisions Equipment Design/Cost Design Norms

Equipment Design/Cost Leaching Tank Crushed seed sent through showers of hexane Easier separation between the phases (ZFS plant tour) Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Waste Processing Solid waste: Rich in sugar and protein, good for animal feed Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Hexane-Oil Separation Goal : 20 ppm Hexane in product oil Problem: How do we model sesame oil in UNISIM? Create hypothetical components Build molecule with UNIFAC model Input known properties Estimate unknown properties Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Hexane-Oil Separation Create component list Hexane Sesame oil → top 4 fatty acids (93%) (Linoleic acid, oleic acid, stearic acid, palmitic acid) Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Hexane-Oil Separation Recover oil from solvent Multiple flash drums Distillation column Design Decisions Equipment Design/Cost Design Norms

Hexane-Oil Separation : Issues with design Multiple flash drums Not enough surface area for good mass transfer Cannot get hexane free oil Distillation column Must heat to the boiling point of oil Does not converge due to lack of component properties Best model: Multiple flash drums +Stripping column Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Final Model 3 flush drums 1-3%wt hexane 1 Stripping column 20 mass ppm hexane Stripping gas Nitrogen

Equipment Design/Cost Cost Estimate Item Cost, USD Capital cost $5,630,000 Utility $507,000/yr Labor $3,650,000/yr Maintenance $3,100,000/yr Material $12,880,000/yr Rate of Return (i): 15% Payback period (n): 20 years Cost Estimate: The study estimate, +/- 35% Purchase Cost: Identify key equipment, estimate their capacity, estimate cost using correlations Capital Cost: scale up for shipping, accessories (pumps, pipes, valves, etc), and plant set up Utility: Steam Labor: 15 people running the plant Maintenance: 3% of purchase cost Material: Based on material balance and market price Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Cost Estimate Breakeven oil price: $2,670/t Market oil price: $2,870/t (BEP is 7% lower than market price) → GREAT! There is room for profit. Acknowledge that many assumptions used in the current cost estimate are not verified. That need to be done in the future. Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Design Norms For this project, we will focus on Transparency Stewardship Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles

Equipment Design/Cost Progress & Obstacles Update cost optimization Solid handling system - limited knowledge (Grinder, leaching, etc) Team members Project Summary Design Decisions Equipment Design/Cost Design Norms Progress Obstacles