developing low coast essential oil distilation plant

mechanical design

1. BY: GIRMA G & FILIMON KBY: GIRMA G & FILIMON K
Advisor-Abebe k Advisor-Abebe k
Mesele H.Mesele H.
Well comeWell come
toto
final year project presentationfinal year project presentation
onon
DEVELOPING LOW-COST ESSENTIAL DEVELOPING LOW-COST ESSENTIAL
OIL DISTILATION PLANTOIL DISTILATION PLANT

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contentscontents
•Objective of the project
•Introduction
•Production of essential oils
•Design approach
•Distillation plant design
•Conclusion & recommendation

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Objective of the projectObjective of the project
The objective of this project is to design a low cost essential oil
distillation plant, which can be manufactured in medium workshops
using locally available materials.

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LimitationsLimitations
•References books are not available .Even though some information is
available in certain web sites their technological background is not
given due to copy right.
•Since the industry is not common in our country, we face a problem to
get experimental data, which are important for the design of the
distillation plant

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Introduction Introduction
what are essential oils
Essential oils :-are distilled volatile oils of plants materials that
have strong aromatic components. These aromatic substances are
made up of different chemical compounds that occur naturally in the
plant. For example, alcohol, hydrocarbons, phenols, aldehydes, esters
and ketones are some of the major components.
The only theories for calling such oil "essential" are
that the oils were believed essential to life and they
were the "essence" of the plant.

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Economic value& their useEconomic value& their use
Direct culinary use
Perfumery ,cosmetics ,household and personal hygiene
products
(perfumes & sprays-creams-deodorants……
In food and drink industry as flavoring agent &preservatives
Inhuman and veterinary medicine as component of
pharmaceutical preparations
In crop protection as pesticide and repellents
Due to these wide applications of essential oils
The worldwide market for essential oils has been estimated at US$2.6
billion, with an annual growth rate of 7.5%
Africa share is < 1% of this market

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•Ethiopia is blessed with fertile soil, which can
produce a wide variety of aroma plants suitable for
the extraction of essential oils for use as food
flavorings, fragrances, aromatherapy products or
pharmaceuticals.
•Therefore there is potential for creating a new agro-
industry in Ethiopia, an industry, which could create
higher earnings from land use, as well as create job
opportunities both on the land and in the
manufacturing.

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Distillation
-water distillation or "hydro distillation"
-water and steam distillation or "wet steam"
-steam distillation or "dry steam"
Solvent Extraction
Carbon Dioxide Extraction
Cold Pressing
Production of essential oilsProduction of essential oils

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DistillationDistillation
“the art of distillation is the act of the invisible being
made visible”
...Jeanne rose 2001
The vast majority of true essential oils are produced by
distillation. There are three basic types of essential oil
distillation:
water distillation ( "hydro distillation" )
water and steam distillation
Steam distillation

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Water distillationWater distillation
•The Principle is to boil suspension of an aromatic plant material and water so that
its vapor can be condensed

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……contcont
Advantages
The stills are of the simplest type and are used extensively
by smallholder producers of essential oils
used in rural areas where boiler is not available
Disadvantage
heat is difficult to control and hence the rate of distillation is variable
possibility exists for local overheating and "burning" of the charge
which can lead to a poorer quality oil.
it requires the heating of a large quantity of water adding to costs
and time needed for each distillation
It is a slower process than other methods hence less energy efficiency

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Steam and water distillationSteam and water distillation
Water & steam distillation is an improved method, the still
contains a grid which keeps the plant material above the water
level .
The water is boiled below the charge and "wet" steam passes
through the plant material.

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….cont
Advantage
as compared to water distillation
it gives higher oil yield and quality
it is faster process than water distillation so it is
more energy efficient
Disadvantage
since the steam in the process is wet it makes the
plant material quite wet this will slow down the
distillation

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Steam distillationSteam distillation
The most advanced type of distillation is by direct steam provided
from a separate boiler. The still contains a grid plate under which
an open steam pipe is fitted
advantage
Lower risk of thermal degradation as temperature generally not above
100°C
The amount and pressure of steam can be controlled
Steam distillation gives higher oil yield and since it is a faster process
than other distillation methods so it is more energy efficient.
disadvantage
it is expensive
Requires higher level of technical skill and fabrication and repairs and
maintenance require a higher level of skill.

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Steam distillationSteam distillation

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Steam distillationSteam distillation

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DESIGN APPROACHDESIGN APPROACH
Production method selection
Energy modeling
Experience from other countries &
essential oil distillation plant at
wendo genet

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Production method selection
 steam distillation is selected for the production of the essential oil.
steam distillation:
Gives higher oil yield and good quality oil
An obvious drawback to steam distillation is that, higher capital
expenditure needed for the steam generator (boiler)

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Energy modeling
According to their local availability and their world, market class four local aromatic plants
are selected
Latent heat of vaporization of oil components (L)
Amount of water in the plant material (M
w)
Amount of Oil in the plant material (M
oil)
Energy required to vaporize the oil (E
oil)
Energy required to vaporize the water (E
water
)
Heat gained by the plant material (H
gained
)
Then the total amount of energy required (E
total
)
E
total=E
oil +E
water +H
gained
Amount of steam required (M
steam)
M
steam=E
total
/h
g
M
steam
=30.2 kg

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Essential oil production in
Papua new guinea

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Essential oil production at
wendo genet

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DESTILATION PLANT DESIGNDESTILATION PLANT DESIGN
•The steam distillation process for the extraction of essential
oils from plant material consists of four basic parts:
The steam generator or boiler
Still or retort
Condenser and
Oil separator

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Steam generatorSteam generator

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•Volume of the tank V=80 L
•Pressure inside the tank P= 0.34 Mpa
•Material used is steel (st-37)
Steam generator tank designSteam generator tank design

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steam generator mountingssteam generator mountings
•steam generator mountings

Pressure gauge
Safety valve
Flow control valve
Pressure reducing valve

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Still or retortStill or retort
Consists of:
• basket and
•Perforated plate

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SeparatorSeparator

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CondenserCondenser
Coiled Tubular Condenser
•Easy to make
•Poor heat transfer
•High pressure build-up
during distillation
Multiple Tube Condenser
•requires shop manufacture
•Good heat transfer
•No pressure build-up
Considering the advantages , multi tube condenser is selected for
the design

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Condenser designCondenser design
Saturated steam enters to condenser at 100
0
c (T
1
).
Saturated steam leaves the condenser at 60
0
c (T
2).
Cooling water is at room temperature at 20
0
c (t
1).
Mass flow rate of water at shell side m
w
=1.66kg/sec.
Mass flow rate of steam at tube side m
s=0.0117kg/sec.
Then the following results are obtained
Number of tubes required 20(1/2” pipes, O
D=12.7mm,I
D=7.16mm)
Length of each tubes , L
tube=1.03m
shell dimension :I
D=200 mm,wall thickness, t=2mm
Baffles spacing , B=70mm.

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CONCLUSIONCONCLUSION
 Essential oils play a great role in the economic development of a country
Steam distillation gives high quality oil
the energy production unit (steam generator) takes much of the cost of the
distillation plant.

In this design a locally manufactured, low-cost steam generator substitutes the
boiler. Therefore the overall cost of the distillation plant is significantly lowered
From the energy modeling it is found that much of the energy given to liberate the
essential oil from the plant material is taken by the moisture inside the plant.
Therefore it is important to know the optimum moisture content of the plant before
the distillation process.
Moreover, to have high quality oil, the still, condenser and separator should be
constructed by stainless steel. Because other materials like iron, copper and
aluminum react with essential oil and affect the quality of the oil.

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RECOMMENDATIONSRECOMMENDATIONS
wood is least sustainable energy source; it is recommended to use other low cost
fuel like rubber, trashes and chips from woodwork shops as source of energy
In addition, it is possible to incorporate a solar water heater in to the system to
preheat the water before it enters the steam generator
To reduce heat loss from the pipes and the body of the still, insulation is very
important. For this purpose locally available materials like sacks and cotton can be
used.
Separation of oil whose density is very close to water or one of the major
components of the oil has a density greater than one while all of the others have a
density less than one is more difficult. To avoid such problem the temperature of the
condensate must be maintained above 50
0
c
The distillery site should have the following requirements
ample availability of water
closed proximity to the plant material that will be distilled

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THANKTHANK YOU YOU