Magellanium Technologies Pvt. Ltd.

Park Street, Kolkata, West Bengal

As we know, Biodiesel is the renewable alternative to petroleum-based High-Speed Diesel (HSD) that we widely use in our cars as fuel. Fat from vegetable and animal sources exists in the form of triglyceride (one form of ester), which, despite having comparable calorific value, is not suitable for direct use as motor fuel due to its higher viscosity, poor combustion & cold flow properties. Alteration of its molecular structure, as we call it Transesterification, of such fat came up as the only solution to unleash its goodness other than human consumption. Fatty Acid Methyl Ester (FAME), the scientific name of Biodiesel, is the substance that is achieved by the process of such Transesterification.
Various chemical processes are practiced worldwide to make the process happen :

• Heterogeneous Base Catalytic Transesterification.
• Heterogeneous Acid Catalytic Transesterification.
• Homogeneous Base Catalytic Transesterification.
• Homogeneous Acid Catalytic Transesterification.
• Enzymatic Transesterification.

This nomenclature is based on the type of catalyst used in the chemical reaction process adopted. Amongst them, Homogeneous Base Catalytic Transesterification wins the fight and emerges as the industry standard due to its several advantages over the other ones with respect to reaction time, temperature, and, most importantly, the economy.
Now, even if we come this far in choosing the most suitable reaction process, the quest does not stop here. By virtue of its being an industrial chemical process in a Biodiesel plant, it entails a number of unit processes and unit operations going into shaping the final product with the desired quality and without compromising on the process economy. Three sections where we can do engineering and optimization are Preprocessing of FeedTransesterification.Washing & Refining.

Preprocessing of Feed :

• It is often underrated but has a great influence over the processes forward. At the same time, the type and quality of feed dictate the design of the preprocessing unit. Feed with low FFA content (<3%) gets by only with screener and homogenizer assembly as no unit process happens at this stage. This operation aims at rendering the best possible homogeneous feed without any particulate impurity fit for Transesterification.
• Conversely, Feeds with high FFA content (>3%) are not fit for direct Transesterification to be parsed through, as the containing FFA begets soap, the most undesirable outcome, affecting the reaction stoichiometry adversely to result in incomplete Transesterification. Here comes two choices - to get rid of the FFA content and bring down its concentration below the permissible limit or to transform the FFA to triglyceride (one form of ester). Now, the feed is ready for the next step.
• Backed by decade-long research data, we have mastered the science of designing the preprocessing unit that suits the feed available in your locality. Ours is a unit that personifies engineering excellence in terms of both space and cost optimization without compromising on the quality of output. As one of the leading biodiesel plant manufacturers, we work on the principle called co-creation, in which we continuously collect operational data from existing plants and then implement meaningful fine-tuning in the next product we release based on that data processing.

Transesterification :

• The core of the whole process line happens inside a vessel called the reactor, which plays the most important role in FAME production, be it its quality, quantity, or cost optimization. Without exception, we also adopt the same type of Transesterification technology, i.e., Homogeneous Base Catalytic Transesterification, to run our modular batch reactor, which exemplifies our specialization in designing one of the finest reactors available across the industry. For the days of toiling, our primary focus used to be obtaining the highest-ever possible reaction conversion along with the lowest residence time, which we eventually achieved to stay extremely relevant to the industry.
• Another useful aspect of such optimization is observed in the next process of washing and refining going forward. The design of the reactor defines the challenges we are going to put on the next step, be it the extent of atomization of glycerol, soap, water formation, and most importantly, the undesirable intermediate products, such as mono/dy/tri-glyceride content in the Biodiesel. Now, the effort put into crafting such an engineered reactor started making sense.  

Washing & Refining : It is paradoxical why most of us don't pay equitable heed to this section because this section holds the key to enhancing the look & feel and the acceptability to different standards (BIS, ASTM, EN, etc.), no matter what kind of Biodiesel the reactor spits out. What we get from the outlet of the reactor is crude Biodiesel, a mixture of FAME, Glycerol, and loads of undesirable other impurities. An equipped biodiesel plant in India makes sure that the technology is capable of refining the crude Biodiesel and making it industry-ready.
Crude Biodiesel has to be parsed through several unit processes and operations to make the final output FAME be accepted as the standard B100.

Bioethanol, a renewable energy source, is produced from organic matter using state-of-the-art, energy-efficient production technology utilized in a biofuel plant in West Bengal. It is a readily available, clean-burning fuel for combustion engines that blends seamlessly with gasoline. It serves as a viable alternative to petrol in road transport vehicles, significantly reducing traffic-related greenhouse gas emissions.

MAGTECH’s Bioethanol Plant: Transforming Biomass into BiofuelOur bioethanol plant in India employs the latest advancements in second-generation (2G) bioethanol technology. Unlike first-generation (1G) bioethanol production, which relies on food crops like corn and sugarcane, 2G bioethanol is produced from inedible agricultural residues34. This includes materials such as corn cobs, rice husks, wheat straw, and sugarcane bagasse.
These materials are converted into cellulose, which can then be fermented into ethanol and mixed with conventional fuels. This process not only provides a sustainable energy solution but also addresses the critical issue of agricultural waste management. These are why Bioethanol plant manufacturers are being endorsed as sustainable solutions.

The Process: An In-Depth LookThe production process in our bioethanol plant in West Bengal involves four major steps :

• Pretreatment: The lignocellulosic biomass feedstock undergoes pretreatment to prepare it for the subsequent processes. This involves breaking down the complex structure of the biomass and making the cellulose more accessible.
• Hydrolysis: The pretreated biomass is then subjected to hydrolysis. This process involves breaking down the complex carbohydrates into simple sugars using enzymes. The result is a sugar-rich solution ready for fermentation.
• Fermentation: The simple sugars are fermented by microorganisms to produce ethanol. This process is carefully controlled to ensure optimal conditions for the microorganisms.
• Distillation: The resulting mixture is distilled to separate the ethanol. The ethanol is then dehydrated to remove any remaining water, resulting in anhydrous ethanol ready for blending with gasoline.

Why Choose MAGTECH?Choosing MAGTECH’s bioethanol plant over other suppliers offers several distinct advantages :

• Innovation: At MAGTECH, we pride ourselves on our innovative approach to technology. Our bioethanol plant consultant in India leverages cutting-edge 2G bioethanol technology, setting us apart from competitors who still rely on 1G technology.
• Efficiency: Our biofuel plant operates with high efficiency, maximizing ethanol production while minimizing waste.
• Sustainability: By using agricultural waste as feedstock, our plant promotes sustainability and contributes to waste management solutions.
• Support: We provide comprehensive after-sales support to ensure your plant operates smoothly and efficiently.

MAGTECH’s Unique Selling Proposition (USP)MAGTECH stands out in the market with its unique selling proposition (USP). Our USP lies in our commitment to innovation, efficiency, and sustainability. We offer a unique product - a bioethanol plant in India that uses advanced 2G technology and agricultural waste as feedstock. This not only sets us apart from our competitors but also aligns with the Indian government’s target of 20% ethanol blending in petrol by 2025.
Our goal is not just to sell a product but to provide a comprehensive solution that contributes to India’s energy independence and promotes sustainable practices. Stay tuned for more updates as we gear up to supply this revolutionary product shortly.

We are pleased to highlight our recent breakthrough in oleochemical plant design and manufacturing that sets new standards in fat-splitting technology. Our state-of-the-art fat-splitting plant incorporates cutting-edge innovations across all facets of lipid processing:

1. Cutting-Edge Reactor Design : Our fat-splitting plant features uniquely engineered reactors crafted for unmatched process control. The reactors allow ultra-precise regulation of key parameters like temperature, pressure, and reaction time to optimize the complex fat-splitting reactions. Our multiple reactor configuration also enables tailored reaction conditions for different feedstocks. The entire reactor system is automated for consistent, high-quality output.

2. Revolutionary Catalyst Formulation : We have developed proprietary high-performance catalysts that accelerate fat-splitting reaction kinetics for increased throughput and purity. Our catalysts are optimized for activity, lifetime, and regeneration properties to minimize costs. We can also customize catalysts for specific feedstock properties.

3. Advanced Separation Techniques : Our plant employs cutting-edge fractionation solutions for separating and purifying the various products and by-products after the fat-splitting reactions. We utilize a sophisticated multi-stage vacuum distillation system to leverage differential volatility for fractionation. Our distillation columns are equipped with structured high-efficiency trays and optimized reflux flows for sharp component splitting. We also integrate heat pump thermal coupling and multi-effect evaporation to minimize energy usage and maximize heat recovery.
Additionally, we implement high-selectivity membrane separation as a complementary fractionation technology. Our ultra-thin zeolite and ceramic membranes preferentially permeate fatty acids over other components for enhanced efficiency. We can incorporate an array of membrane modules in series and parallel arrangements for incremental fractionation power.
The combined distillation and membrane separation system allows exceptionally high purity isolation of individual fatty acids like oleic acid and stearic acid to over 99% purity. It also fractionates glycerol, mono- and di-glycerides, and other minor by-products into pure streams. Our analyzers and control systems continuously monitor all outputs to ensure consistent separation performance. This superior fractionation capability is essential for producing on-spec products and feedstocks for downstream processing.

4. Customized Scalability : We have unmatched expertise in scaling fat-splitting plants from lab bench to full-scale industrial capacity. Our reactors and separators are modularly designed for flexible capacity. We can tailor the plant's sizing and configuration for customers' specific production needs.

5. Sustainability Focus : Our plant is engineered to minimize environmental impacts through solvent-less and low-waste design, heat integration, and recycling of process side streams. We also optimize energy and water usage for reduced consumption.

6. Comprehensive Support : Our comprehensive services span techno-economic studies, process design, equipment supply, on-site installation, and commissioning. We also provide personnel training and long-term maintenance support. Our multi-disciplinary expertise covers the entire plant lifecycle.
With an unrelenting focus on driving innovation across every plant component, we are redefining the future of fat splitting. This technology will benefit diverse industries, from Biodiesel to pharmaceuticals. We invite you to learn more about how our fat-splitting plant can transform your lipid processing operations into a new era of efficiency, precision, and sustainability. Reach out to our team to leverage our technical edge in your oleochemical processes.

Backdrop :Glycerine, as we know, has diverse utilities across industries around the globe. Food, pharmaceuticals, and cosmetics are the major consumers among them. Unfortunately, India still has a lot to do about tapping the opportunity of global export, which stands at a meager 0.33% only with respect to the global demand. Such a pitiful scenario may be ascribed to quality and costing issues persistently plaguing Indian glycerine refining industries.
We have a pretty straightforward solution to this problem and have a well-thought-out plan that can potentially give a huge boost to our industry. But before we get into these details, let's have a discussion on how the thing works and how we are so relevant to this.

How does glycerine refining work? Crude Glycerol sourced from various industrial chemical processes such as Oil Processing, Fats Splitting, Hydrolysis, Saponification, Transesterification, etc., are parsed through a series of following unit processes and operations to achieve the desired purity of glycerine. As one of the leading glycerine refining plant manufacturers, here, we have walked you through the process of purification of glycerine.

Step 1 : Glycerine Intake and Pretreatment:
The process is defined by the feeding of crude glycerol laden with various impurities, including methanol, salts, soap, fatty acids, and undesirable odor compounds, from the said sources. The objective of this section is to unburden the feed from particulate impurities, soap, methanol partially, and water and homogenize the mixture to make it a perfect feed for the next section.
Treated with sulphuric acid, the soap and free oil content is transformed into free fatty acid, which is neutralized and removed by caustic lye. Following this, running through a decanting chamber or column, the glycerol is stripped of all lightweight impurities by phase separation in order to get more pure glycerol.

Step 2 : Dehydration: Glycerol, typically obtained from the previous step, contains residual water and methanol along with other miscible impurities. We engineered the flash removal unit for methanol and then the heat exchanger for moisture removal to ensure maximum removal efficiency with low energy cost.

Step 3 : Decolorization: The Crude glycerol can exhibit a dark color due to miscible impurities and contaminants. Decolorization is the art of restoring clarity to glycerine. We designed a bleaching unit in which activated carbon or other specialized adsorbents are applied to treat the glycerine stream, which selectively captures and removes color-causing impurities. Following this, thorough filtration or centrifugation ensures the glycerine emerges with a pristine appearance.

Step 4 : Distillation for Purity: Perhaps one of the most important, if not the most important, of all the steps is distillation. It serves a dual purpose: separating glycerine from water and further purifying it by removing volatile impurities. In the distillation column, heat is applied, glycerine vaporizes, and under carefully controlled conditions, it is separated from water, which typically exits as the bottom product. This process results in glycerine of remarkable purity. Our specially engineered multi-stage distillation column also ensures maximum efficiencies in intended action with remarkably low energy costs. This sets us apart from the run-of-the-mill glycerine distillation plant manufacturers.

Step 5 : Deodorization for Quality: Residual odor challenges the acceptability of the finished pure glycerine in certain industries, such as cosmetics and pharmaceuticals. In our deodorization step, any residual odors or flavor compounds are meticulously removed. The result is glycerine that not only meets high purity standards but also surpasses expectations in terms of odor and taste.

Why a Precision Glycerine Refining Plant is relavant?In the global market, the acceptability of glycerine hinges on some factors- purity, color & odorlessness, and pricing. To harness the full potential of glycerine, it must undergo meticulous refining to ensure it meets the stringent standards set by various countries and their industries. This is what all the glycerine refining plant suppliers in India aim for in the contemporary market.

MAGTECH Advantages:

• Purity Is Paramount: This is the primary attribute that is met in the first place. As discussed earlier, the purity of glycerine is non-negotiable, especially in pharmaceuticals, cosmetics, and food processing; any trace of impurities or undesirable odor can run its chance of rejection by the downstream industries. Achieving such purity demands precision and expertise on the part of the manufacturer. And, we stand hand in hand to pledge such high efficiency of your plant every time.
• Cutting-Edge Technology: Our state-of-the-art machinery and equipment are meticulously crafted to deliver consistent and superior results with a primary focus on low CAPEX and low OPEX through low energy consumption. We utilize innovative technologies to ensure that the glycerine refined through our processes is of the highest quality at a very competitive cost.
• Customized Solutions: As in the case of biodiesel plant solutions, here also we recognize that each application has its unique requirements. The most varying part of the whole solution is the type and initial purity of feedstock sourced from different types of industry output. That's why our solutions are customizable to suit the specific needs and scale of your operation, which always indicates cost savings to the clients.