1. Production of Sesame Oil
CEAC REVIEW
Group 20
Golden Oil

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

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

4. 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

5. 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

6. 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

7. 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

8. 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

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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. 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

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

20. 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

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

22. 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

23. 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

24. 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

25. 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