DESIGN OF A PLANT THAT PRODUCES 1000KG/DAY OF LUBRICATING GREASE FROM GYPSUM, WASTE OIL AND SAPONIFIABLE FATS OBTAINED FROM TANNERY WASTE FLESHINGS.

1. DESIGN OF A PLANT THAT PRODUCES 1000KG/DAY OF LUBRICATING GREASE FROM
GYPSUM, WASTE OIL AND SAPONIFIABLE FATS OBTAINED FROM TANNERY WASTE
FLESHINGS.
NAOME PANASHE NYAMBIRA
CAPESTONE

2. INTRODUCTION
► The leather industry is a major polluting industry due to the organic and
inorganic wastes.
► Currently in Zimbabwe there is no waste oil disposal facilities, resulting in
industries disposing oil in unsafe way.
► Creating major environmental problems.
► There is a large deposit of gypsum at Zimphos some of it is sold but still
much of it remain unutilized.
► After looking into detail of waste products being produced from these three
different industries.
► The main purpose of this project is to produce grease using waste oil
gypsum and fats from tannery fleshings.

3. Benefits of project
► Value addition to the fleshings waste from the tannery.
► Renewable component of grease from locally available industry.
► Recycling the waste oil which is causing land pollution.
► Use of waste oil open up a cost effective method to its disposal.
► Raw materials are locally available
► Overall costs of raw materials are cheap
► Utilizing large deposit of gypsum at Zimphos

4. LITERATURE REVIEW
► Grease, is a lubricant, it is much thicker than oil and is used in other
areas of your machine or vehicle.
Grease Anatomy

5. Types of grease
Calcium grease
Sodium grease
Aluminium grease
General steps of grease production
► Saponification
► Dehydration
► Addition of waste oil
► Addition of additive
► Homogenizing
► Test for suitability
► Packaging

6. EXPERIMENTAL RESULTS AND ANALYSIS
► The following experiment were carried out.
▪ Determination of Fat content of fleshings.
▪ Chemical characterization of extracted fleshing fat oil.
▪ Preparation of the calcium soap thickener.
▪ Preparation and formation of grease and determining the optimum
parameters

7. Experiment 1
Determination of Fat content
► Can safely conclude that fat content in the fleshings is around 50%.
Characterization of fats obtained from fleshing
► All results were falls under the standard value that is 180 -233 ml.N/meq.
Sample Fleshing (grams) Fat (grams) Fat content (%)
A 800 408.8 51.1
B 600 312 52
C 400 203.2 50.8
Sample Weight of sample (grams Saponification value
(ml.N/meq)
A 5g 186
B 5g 192
C 5g 189

8. Experiment 2
To determine the ideal proportion of thickener and waste oil.
Table 5 proportion of thickener and waste oil.
sample %waste oil % thickener Drop point 0C
ASTM D566
Oil separation ml Description
A 80 20 140 38 Fluid
B 70 30 165 20 Semi fluid
C 60 40 170 13 Firm fluid
D 50 50 175 8 Semi solid

9. Graphs of variation of drop point and oil seperation
with varied proportions

10. Experiment 3
To determine the optimum mixing temperature
sample Mixing Temperature
0C
Drop point 0C ASTM
D566
Description
A2 25 162 Very firm
B2 50 165 Firm fluid
C2 80 167 Semi fluid
D2 100 170 Fluid

11. Physical analysis on best formulation
Test/ parameter Result
Drop Point ASTM D566 167 0C
Description Semi fluid
Proportion of thickener and waste oil 60: 40
Mixing temperature 80
Oil separation 13 ml

12. Discussion and conclusion on Experiment
► The higher the proportion thickener the greater the drop point.
► As the amount of waste oil increases, the consistency of grease transforms
from semi fluid to very soft.
► Small percentage of thickener results in grease loose the stability and the
oil separation become higher.
► The drop point is affected by mixing temperature since as we increase
temperature the viscosity of oil also increases
► The grease formulated had shown overall good performances from the
ASTM standard method of testing.
► Thus, it can be concluded that grease can be formulated using waste oil as
the base oil and gypsum soap as a thickener

15. Block flow diagram for production of grease

16. Process flow diagram for production of grease

17. Mass balance
► The objective of this project is to produce 1000kg/day of grease.
► Assuming 10 working hours per day, 100kg/hour of grease is produced.
► The balance is to be carried out starting with the final stage since the value
of the product is known.
► Therefore mass balance determines the feed and the components for each
stream.
Overall mass balances per day

18. Energy balance
► The conservation of heat energy in the heat transfer equipment shall be
illustrated by considering heating and drying operations in the process.
► According to the first law of thermodynamics conservation of energy can be
expressed as; Energy out = energy in + generation – consumption –
accumulation
summary of energy balance.

20. Batch reactor design procedure
► Reactor Design According to (Sinnott, 2014)
► Batch time
► Reactor volume
► Height and Diameter of Batch reactor
► Cross sectional area of the reactor
Mechanical design
► Maximum allowable pressure
► Wall thickness
► Outside diameter
► Design temperature
► Heating coils
► Design of the agitator
► Support system design

21. Batch reactor design parameters

22. Dryer design procedure
► Outlet temperature of air
► Log mean temperature difference
► Amount of air required
► Area and diameter of dryer
► Length of the drier
Mechanical design
► Design pressure
► thickness of the drier shell
► Inner and outer diameter of the Drier
► power required by the Blower
► power required by the Exhaust fan
► diameter of the feed pipe
► Diameter of the air inlet and outlet pipe:

23. Dryer design parameters

24. PROCESS CONTROL AND HAZOP ANALYSIS

25. Process control for the saponification
batch reactor

26. Process control for rotary dryer

27. HAZOP analysis saponification batch reactor

28. HAZOP analysis on a dryer

29. SITE SELECTION AND PLANT LAYOUT

30. Description of the suitable site A
This site is situated in the Willovale industries near Superior Holdings were
one of the raw materials is obtained which is tannery waste fleshings.
Glenview industrial area map

31. Description of the suitable site B
Masasa Park industrial area map.
This site is situated in the Masasa Park industrial area near Zimphos were
one of the raw materials is obtained which is gypsum

32. The plant layout of the Grease production plant

33. ENVIRONMENTAL IMPACT ASSESSMENT

34. Objectives of an EIA
► To evaluate the Project likely impacts on the environment.
► Identifying necessary actions to minimize negative impacts
► To assist in ensuring environmentally and socially sound management of the
project
► To provide information on the environmental consequences for decision
making.
The environmental laws and regulations of
Zimbabwe that are relevant
► The Environmental Management Act (Chapter 20:27) No. 13 of 2002
► Water pollution prohibition (section 57)
► Standards for Waste Management (Section 69-76)
► Water Act (Chapter 20:24)

35. Positive impacts
► Employment creation.
► Improved income levels and standard of living for the community.
► Stimulation of secondary industry like home.
► Foreign currency earnings when grease is exported.
► Improvement to the national economy
► Recycling of waste materials generated on the environment.
► Recruiting locally, non-technical staff.

36. Environmental negative impacts
Site clearance and preparation impacts
► Loss of natural habitat and biodiversity,
► Nuisance dusting, Noise
Construction impacts
► Earth material sourcing, Materials transportation,
Operation impacts
► Air and Climate, Water supply, Ecology and biodiversity, Human
Environment
Decommissioning impacts
► Unemployment rate increase

37. Corporate, social and environmental
responsibility
► Recruiting locally, particularly non-technical staff
► Onsite housing for staff.
► Developmental projects e.g. sinking of boreholes in the community to
improve access to water.
► Charity work such as assisting under privileged children with school fees.
► Promote going green campaigns such as planting of trees.
► Maintain good public relationship with the traditional leaders.
► Respect their culture.

38. FINANCIAL ANALYSIS

39. Objectives
► Capital Cost estimation
► Total Annual Production Costs
► Manufacturing Costs
► Sales Revenue
► Profitability evaluation
Profitability indicators used include
► Return on Investment (ROI)
► Payback period (PP)
► Net present value (NPV)
► Breakeven point (BEP)

40. Cost estimation of purchased equipment
► Equipment prices in the data booklet from Coulson and Richardson.
Cost basis mid 2016
► Designer used factorial method for estimation of material cost and
also the total capital investment
► Cost were done using the data booklet from Coulson and Richardson
volume 6 .using the formulas
► Ce= CSn
► Purchase cost of equipment = Bare cost x Material factor x pressure
factor
► Purchase cost of equipment= Bare cost x Type factor x pressure
factor

42. Updating the cost using the cost index
►

43. Total Capital Investment
► Direct costs = $929 340
► Indirect Costs = $1 301 076
► Total fixed capital = Direct costs + Indirect Costs
= $ 2 230 416
► Assuming that the working capital was 10% of fixed capital investment
► Working capital = 0.1 × $ 2 230 416
= $223 041.6
► Total Capital investment = fixed costs + working capital
=$ 2 453 457.6

44. Total Production Costs
► Total product cost consists of Manufacturing Costs and General
Expenses.
Assumptions
► Cost of utilities is 10% of direct costs
► Maintenance and repair cost 5% of Fixed Capital investment
► Operating labour and supervision costs 10% of direct costs
► Laboratory and Other Service Costs is 10% of direct costs
► Miscellaneous 10% of maintenance costs
► Capital Charges is 10% of total fixed capital
► Insurance was assumed to be 30% of the total fixed capital

45. Total Production Costs
► Total fixed costs = $1 200 706
► Total variable costs = $198 135
► Total plant overheads = $196 276.5
► General Expenses = $ 79 755.95
► Therefore, the total manufacturing cost = $ 1 595 117.5
Sales Revenue
► Annual production = 384 ton/year
► Production cost /ton = $4 361.64 per ton
► Assuming a profit margin of 50%
► The selling price = $6 542.47 per tone
► Gross Income = $ 837 436.92
► Let the Tax rate be 10% of Gross income
► Net Profit = $ 753 693.23

46. Profitability evaluation
► Payback period = 3.4years
► Return on investment = 29.7 %
Breakeven Analysis
► From the break-even we need to sell 1 022.7 tonnes to start making
profits.

47. Net Present Value
Year Net Cash Flow ($) Discounting factor Present value ($)
0 -2 230 416 1 -2 230 416
1 753 693.23 0.909 685 107.14
2 753 693.23 0.826 622 550.60
3 753 693.23 0.751 566 025.86
4 753 693.23 0.683 514 772.47
5 753 693.23 0.641 483 117.46
6 753 693.23 0.564 425 082.98
7 753 693.23 0.513 386 644.62
8 753 693.23 0.466 351 221.10
9 753 693.23 0.424 319 565.92
10 753 693.23 0.38 286 403.42
Total 5 306 516.3 - 2 806 236.03

48. CONCLUSION
► Process design and equipment design for a plant that produces grease
was successfully done.
► Experimental work was carried out to depict optimum process
conditions for the production of grease.
► The results from the experiments were used in the mass and energy
balances and these were then used to design the process and
equipment.
► An environmental impact assessment was done. Mitigation measures
for all negative impacts were prescribed.
► A detailed financial analysis was carried out with the results proving
the project is economically feasible.
► The project has a Return on Investment 29.7% and a Payback period of
3.4 years.
► It can be concluded that it is possible to produce 1000kg/day of
lubricating grease from gypsum, waste oil and saponifiable fats
obtained from tannery waste fleshings.

49. RECOMMENDATIONS
► The yield of grease can be improved through further studies on process
operating conditions
► Further studies should be done to maximize yield of grease and also to
increase the bonding of waste oil and gypsum thickener.
► Further utilization of fleshing that have been removed fat from them since
it’s still waste that is not environmental friendly.

50. REFERENCES
► Bai, P., Li, S., Tao, D., Jia, W., Meng, Y. and Tian, Y., 2018. Tribological properties
of liquid-metal galinstan as novel additive in lithium grease. Tribology International.
► Baum, M.W., ExxonMobil Research and Engineering Co, 2014. High viscosity index
PAO with polyurea thickeners in grease compositions. U.S. Patent 8,772,210.
► Bryant, W.C and Frost .Jr Harold Frost “Grease and grease base U.S.patent
2,594,286
► Cárdenas-Escudero, C., Morales-Flórez, V., Pérez-López, R., Santos, A. and
Esquivias, L., 2011. Procedure to use phosphogypsum industrial waste for mineral
CO2 sequestration. Journal of
► Coppos, A.R.R., Kahn, S. and Borges, L.E., 2018. Biofuels production by thermal
cracking of soap from brown grease. Industrial Crops and Products, 112, pp.561-568
► Dai, Y., Niu, W., Zhang, X., Xu, H. and Dong, J., 2017. Tribological Investigation of
Layered Zirconium Phosphate in Anhydrous Calcium Grease. Lubricants, 5(3), p.22.
► El-Didamony, H., Gado, H.S., Awwad, N.S., Fawzy, M.M. and Attallah, M.F., 2013.
Treatment of phosphogypsum waste produced from phosphate ore processing.
Journal of hazardous materials, 244, pp.596-602

51. THANK YOU