coco-ethanol production of the hilltop coco products enterprises-updated

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I. INTRODUCTION Rationale Practicum is prescribed in the Bachelor of Agricultural Engineering Technology Curriculum, structured to engage in varied individual effective experience for each student in the communities and organizations in the application of Engineering Technology in Agriculture. This exposes the students on the application of technologies and theories they have learned in the classroom with emphasis on farm mechanization, irrigation and crop processing in order to mold them to be more effective and globally competitive future Agriculture Engineering Technicians, trained efficiently in both theoretical and practice know-how, envisioned to be the future mentors of the farmers. Importance of the Practicum

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Page 1: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

I. INTRODUCTION

Rationale

Practicum is prescribed in the Bachelor of Agricultural

Engineering Technology Curriculum, structured to engage in

varied individual effective experience for each student in

the communities and organizations in the application of

Engineering Technology in Agriculture. This exposes the

students on the application of technologies and theories

they have learned in the classroom with emphasis on farm

mechanization, irrigation and crop processing in order to

mold them to be more effective and globally competitive

future Agriculture Engineering Technicians, trained

efficiently in both theoretical and practice know-how,

envisioned to be the future mentors of the farmers.

Importance of the Practicum

The field practice/practicum experience attributed a

unique opportunity for students to acquire skills in

effective application of agricultural technologies and

develop a professional personality that reflects the values

and ethics of the Agricultural Engineering Technology

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Profession in preparation for entry level employment and

efficient technology-based operation of agri-based

enterprises.

Objectives of the Practicum

The conduct of the practicum will provide the

practicumers the opportunity to acquire practical knowledge

in the field, specifically be able to:

1. Gain practical knowledge on the application of

agricultural technologies in coconut farming and

processing;

2. Learn the basics and practical way of producing ethanol

from coconut sap and coconut water;

3. Identify the skills and learnings acquired and problems

encountered by the practicumer during the conduct of

the practicum.

Time and Place of the Practicum

The practicum was undertaken at Sitio Hibabaongan,

Brgy. Washington, Catarman Northern Samar. It was undertaken

from December 2011 to February 2012 or equivalent to 600

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working hours, under the supervision of Engr. Jaime P.

Gilbunela (owner) the Engr. Lidany F. Cornillez(Practicum-

adviser).

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II. HOST PROFILE

Profile and Organizational Setup

In response to the Biofuel Act of 2006 requiring the

blending of ethanol with gasoline, Department of Science and

Technology (DOST 8) through its Provincial S 8 T Center

(PSTC) in Northern Samar initiated a community based project

entitled, “Establishment of a Coco-Nipa Ethanol Pilot

Production Plant in Northern Samar” with Engr. Jaime P.

Gilbuela, PAIE and Associates as the project proponent. The

project is presently situated at Sitio Hibabaongan, Brgy.

Washington, Catarman Northern Samar.

The Project started in 2009, in cooperation with the

office of congressman Paul R. Daza, the provincial

Government of Northern Samar (PGNS), the University of

Eastern Philippines (UEP), Philippine Coconut Authority

(PCA), the Northern Samar Coconut Industry Development

Council (NSCIDC) and with the financial assistance of DOST

Regional Office No.8 thru its Grant-In-Aid program in the

amount of Fifty Thousand Pesos (P50,000). Engr. Jaine P.

Gilbuela was able to fabricate a boiler and still units and

a blower which is now being used in the production of coco-

ethanol through distillation process.

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Trial Test

A preliminary test-run was conducted on February 10,

2010 to test the quality of the locally. Fabricated boiler

and still units and to determine possible adjustment or

modifications preparatory to the final and formal test-run

of the whole production plant. The preliminary test yielded

encouraging and promising results. This give way to the

launching of the first Coco-Nipa Ethanol Pilot production

plant in Northern Samar. The undertaking was attended by the

officials and representatives from the Provincial Government

of Northern Samar. The undertaking was attended by the

officials and representatives from the Provincial Government

of Northern Samar. (PGNS), UEP, PCA, DAR, DTI, DOST-PSTC

Northern Samar and the Northern Samar and the Northern Samar

Coconut Industry Development Council (NSCIDC), Non-

government organizations business groups and the farmers

stake holders as well.

DOST and NSCIDC Inspection

On April 21, 2010, the DOST Inspection Committee and

IDEA Team conducted an inspection of the facilities and

equipment. A test-run was conducted featuring the process of

Page 6: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

coco-nipa ethanol production using the locally fabricated

boiler and still units and other improvised auxiliaries

installed in a shade house made of bamboo, indeed a village

level undertaking. The ethanol produced were tested for

cooking, blowtorch operation, fuel blending (10%) for two

stroke engine. The “Lambanog” a low-proof ethanol by product

also served as beverage. DOST 8 facilitated the submission

of product sample to the Industrial Technology Development

Institute (ITDI) of DOST at Bicutan, Taguig City, Metro

Manila for alcohol content analysis.

All tests undertaken during the said activity, also

showed encouraging and promising results to warrant

viability of the project both technically and economically.

Engr. Gilbuela won the first prize for the Likha Award

or outstanding utility model for his “Design and Fabrication

of Equipment to produce Bioethanol from coconut sap” during

the 2011 DOST-Sponsored Regional Invention contest and

exhibition held last August 22-25 2011 in Tacloban City.

Products

Page 7: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

The following are the main products produced by the

plant:

a. Primary Products

1. Coco-nipa ethanol fuel(bioethanol)

- Can be blend in gasoline for internal combustion

engines and for household cooking.

2. Coco-nipa low proof beverages

- Commonly known as “lambanog”

3. Coco organic vinegar

- Widely used in every household for cooking,

preservatives and other production using vinegar.

b. Secondary Products

The following are the secondary products produced.

1. Perfumes 5. Wines

2. Colognes 6. Solvents

3. Sanitizers 7. Anti-freeze

4. Energy drinks

III. PRACTICUM

Page 8: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

PROGRAM OF ACTIVITIES

Practicum provides opportunities to go through the

actual methodologies of a specific job using the real tools

and equipment and also learn its processing method and

techniques. In effect, the workplace becomes a development

venue for a practicumer to learn from school.

This section narrates the activities that the

practicumer had gone through during the operation. This also

includes observation, participation, and interaction during

their operation. Practicum is an important way in which

students acquire relevant knowledge and skills at work.

The practicum started with an orientation to inform the

practicumer about the plant’s equipment and processing

procedure with the owner, Engr. Jaime P. Gilbuela. The

practicumer were permitted initially to observe the entire

operation. The next operation, the practicumer were allowed

to help the workers. We provided fuel such as wood, coco

shell, and husk to be fed on the furnace and put water into

the tank through its cooling system.

Time came when the practicumer first handled and

operated the machine; the still/column. The practicumer

learned that the still is the principal part wherein a

Page 9: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

constant temperature would be maintained during operation.

As a routine before operation…

Observation

The practicumer observed that the brew to be charged

should undergone its fermentation before charging observed

especially the boiler and the container used. The water on

the cooling system should be clean and strained well to

avoid dogging in the pipes. The plant advantage is that

there is no thrown away on the brew being charged.

Participation

The trainee participated in its normal operation of the

plant by checking important spots like the furnace, boiler

and mostly the thermometer in the still. When trouble

happened to the equipment during the progression will cause

a big interruption on the whole process. They participated

also in processing its vinegar.

Interaction

During the training, the practicumer learned to

interact with other people. He knows that people have

Page 10: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

different characteristics and attitudes, however, making

friends with the trainee’s co-workers wasn’t make difficult.

Even though he was only a trainee, they didn’t treat

him like trainee but an equal. As a practicumer, he didn’t

feel uncomfortable as he worked with them, form the

interaction the practicumer had with the workers and owner

of the plant, he learned to work with patience. Although

thoroughly working on something was time consuming, the

quality of the output/product is the most important. He also

learned his co-worker’s experiences and mistakes that he can

apply whenever he needed them. They also encouraged the

practicumer to go on with his studies until he become

professional. Although practicumer worked and interact with

them, the skills and techniques that they shared with him

which cannot be found from books.

SIGNIFICANT LEARNING’S AND INSIGHTS

Insights on Coconut Tree

Page 11: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

Coconut (Cocos nucifera L.) is a large palm, growing up

to 30 meters (98ft) tall, with pinnate leaves 4-6 meters

(13-20ft) long, and pinnae 60-90cm long; old leaves break

away clearly, leaving the trunk smooth, there dwarf and the

b.) tall variety. There are simply distinguished according

to its height. Dwarf coconuts are usually early maturing. It

produces nuts during its. Earlier years compared to the

tall varieties. Tall varieties however yield more nuts than

dwarf varieties. On very fertile land tall coconut palm tree

can yield up to 75 fruits per year, but more often yields

less than 30 mainly due to cultural practices. (Sarian,

2010)

Like other fruits it has thre layers; exocarp,

mesocarp, and endocarp. The exocarp and mesocarp make up the

husk of the coconut. The mesocap is composed of fiber called

coir which have many traditional and commercial uses. The

shell has three germination pores (stoma) or eyes that

removed. Within the shell is a single seed. When the seed

germinates, the roots of its embryo pushes out through one

of the eyes of the shell. (Child,19)

The endosperm or meat is the white and fleshy edible

part of the coconut. Like most nut meat, coconut meat

contains less sugar and more protein that popular fruits

Page 12: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

such as bananas, apples, and oranges. It is relatively high

in minerals such as iron, phosphorus and zinc. The meat in a

green young mature coconut. When the coconut has ripened and

the outer husk has turned brown, a few months later, it will

fall from the palm of its own accord. At that time the

endosperm has thickened and hardened, while the coconut

water has become somewhat bitter.

Coconut water on the other hand serves as a suspension

for the endosperm of the coconut during its nuclear phase of

development, later the endosperm mature and deposit into the

coconut rind during their cellular phase. (Paniappan, 2002)

It is consumed as a refreshing drink and is gaining

popularity as an isotonic sports drink. Mature fruit have

significantly less liquid than young immature coconuts,

barring spoilage. Coconut water can be fermented and

processed into vinegar and alcohol.

The sap derived from incising the flower clusters of

the coconut is drunk as toddy or “tuba” in the Philippines.

Philippines this alcoholic drink is called “Lambanog” or

coconut vodka. A young well-maintained tree can produce

around 300 liters of toddy per year while a forty year old

tree may yield around 400 litters.(Potter, 2005)

Page 13: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

Coconut industry in the Philippines

Coconut industry plays a key role in shaping national

development. It is among the top ten export produce of the

country as exhibited by the good export produce of the both

traditional and non-traditional coconut products. About one

third of the country’s avable agricultural land or 3.26

million hectares is planted to coconut. Representing sixty

eight (68) out of 1.554 municipalities in the country. It

provides a sustainable income source for Filipinos by way of

employment generation. Through its many program. (PCA-

Philippine Coconut Authority)

Unfortunately, despite the numerous coconut plantation

in the country, productivity levels remain low and one of

the reasons may be attributed to lack of information on

appropriate technologies for coconut farming(Banzon and

Velaso, 1982)

Coconut products and by-products

Page 14: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

Coconut is probably known as the “tree of life” because

of the variety of products and by-products made from the

tree.

1. COPRA – is the dried coconut meat. It is the source

where coconut oil is extracted for many uses.

OIL – extracted processed/filtered oil obtained from

copra.

COCONUT MILK – the liquid obtained by pressing grated

coconut meat.

DESICCATED COCONUT – dried coconut grated meat mainly

prepared from food uses.

COCONUT FLOUR – this is the de-aled desiccated coconut

that is finely grounded.

2. COCONUT SHELL – this is the protective covering of the

coconut meat and water. This makes a very good source

of charcoal. This is very good fuel for domestic

cooking.

ACTIVATED CHARCOAL – found to posses the ability to

absorb gases and vapors. Hence finds uses in gas mask,

cigarette filters, removal of bad odors from air

conditioning, freezers, and refrigerators and many

other absorption capabilities.

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CHARCOAL BRIQUETTES – coconut shell charcoal are

processed into briquettes so that it is easier to

transport.

NOVELTY ITEMS – local craftsmen make indigenous

novelties from shells such as lamps, figurines, picture

frames, musical instrument, souvenirs and many more.

3. COCONUT HUSK - Fibrons outer covering of the nut, this

part extent from nut skin to the shell and varying

thickness up to 5cm.

COCO COIR – the hair-like thread extracted from the

coconut husk by mechanical method or by the

decorticating machine.

COCO DUST – are the medium collected after separating

the coir from the husk.

4. COCONUT WATER – the liquid found inside the coconut. It

is the excellent and readily available drinking water.

The quality of water varies according to the age of the

nut. Younger nut water is largely consumed locally as

beverage. Water from nature nuts is used as raw

material from making nata de coco, vigegar, intravenous

fluid, and lector cyte, wine and alcohol.

Page 16: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

5. COCONUT SAP – a very sweet juice obtained from a young

inflorescence locally known as “tuba.”

LIQUOR – coco sap are left to ferment and made into

alcoholic beverage called “tuba”. In Samar and Leyte

Province, they add bark from a local tree and ferment

to produce “Bahalina”. In Southern Tagalog and Bicol

Area, Coco sap are distilled and made into a strong

alcohol called “Lambanog.”

VINEGAR – coco sap are also made into vinegar.

COCO SUGAR – coco sap are sometimes cooked to produce

sugar. This has been a long practice in some places but

not in very large quantities.

COCO ETHANOL PRODUCTION PROCESS

Page 17: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

The production of the coco-ethanol and its by products

undergoes the following processes.

FEEDSTOCK PREPARATIONCOCO SAP/ WATER

BREW FERMENTATION

DISTILLATION

END PRODUCT COLLECTION

Page 18: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

EQUIPMENT USED

The following are the equipment used in the system:

1. Boiler and furnace with chimney

2. Still – bubbler, vapor stripper, condenser (reflex

section)

3. Cooling system with cooling tower

4. Other accessories

a. Batch charging tank c. Fermentation tank

b. Residue receiving tank d. Product containers

Coco ethanol production process first takes place by

collecting coco sap from the farmers. The sap, measuring ten

(10) gallons (37.870 liters) were added with two (2)

kilogram brown sugar and four (4) tablespoon of yeast. The

brew were cleaned and covered in a container for 6 days

fermentation. In fermentation of the brew, the sugar and

yeast are partially converted to alcohol. Next were charging

the brew into the boiler tank in preparation for

distillation.

To separate the ethanol on the brew, distillation

process/method was used. The brew were distilled at a

temperature of 78.4 0C, the boiling point of ethanol then

the brew to be distilled is heated in the boiler. Ethanol

Page 19: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

which has the lowest temperature than water were first turn

into a vapor. The vapor enters the condenser, where it cool

and becomes a liquid again. The collected through a receiver

and drips finally to the container.

The second dripping faucet is a mixture of water and

ethanol called low proof ethanol which drips simultaneously

with the ethanol.

In order to maintain the temperature of the still, it

uses three kinds of cooling system; of which are water and a

controlled air passage into furnace. The first water cooling

system was constantly poured inside the still as soon as

vaporization takes place. If the first cooling system could

not sustain the rise in temperature. The later cooling

system, water and controlled air passage will then be used.

As soon as ethanol was observed to degenerately

dripped, distillation process could be ended to acquire a

good quality ethanol and leaving a small percentage of

alcohol to the residue.

Finally, the residue inside the boiler were left to cool

and drained the day after. Straining it while the residue

collected would be necessary making it dirt free. Sugar and

yeast as desired by the volume of the residue for vinegar

processing.

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SKILLS AND KNOWLEDGE OBTAINED

While operating at the plant, the practicumers find a

way to learn experiences at the same time. “Training by

doing” this is...

V. PROBLEMS ENCOUNTERED AND RECOMMENDATIONS RELATED TO THE

PRACTICUM.

Page 21: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

Problems Encountered

The problems that the practicumers encountered during

his training were all related to the plant’s operation.

Gathering the coco sap to the farmers are often difficult,

the coco sap needed are sometimes not acceptable and sub-

standard thus interrupt the fermentation process.

For fuel used the operation are sometimes wet due to

weather conditions mostly raining.

Weather condition could also affect the operation,

maintaining the temperature of the thermometer of the still

is flexible when the surrounding temperature are too hot and

cold.

Recommendations

Page 22: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

Based on the observed operations, the practicumers

recommends the following:

A gradual feeding of fuel such as wood, coco shell, and

coco husk to the furnace should be done in order to

maintain its temperature.

Because distillation is the major energy-consuming

stage, such new technology should sought to improve

preferably more advance.

The trainee further recommends an innovation or its

cooling system in aid of controlling evenly the

temperature during operation.

A seminar should be conducted to the farmers

specifically to the coco sap collector for proper

handling and collecting the coco sap.

Page 23: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

COCO ETHANOL PRODUCT COST

PARTICULARS PRICE/UNIT QUANTITY TOTAL

Coconut sap P 10.00/li 40 li P 400.00

Brown Sugar P 35.00/li 2 kl P 70.00

Yeast P 1.00/gram 4 g P 4.00

Labor (Operator) P 300.00/Operation 1 person P 300.00

Labor (Helper) P 200.00/Operation 1 person P 300.00

Fuel P 100.00/ Distillation P 100.00

Total Cost P1074.00

Estimated selling price of the product

Distillation

Product

Selling

price

% recovery

for 10 gal

of products

Recover

ed

volume

Total

Ethanol (H.P.)

Ethanol (L.P.)

Organic vinegar

60/ li

60/ li

25/ li

8%

15%

6%

3.2 li

6 li

30.4 li

P192.00

P360.00

P760.00

Total Product Price P1312.00

Page 24: Coco-Ethanol Production of the Hilltop Coco Products Enterprises-updated

Net Income of Distillation 1312.00

1074.00

P238.00

Monthly Net Income Per

15 Distillation Run 238 x 15 = P3570.00

Year Net Income 3570x12 = P42840.00

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COCO-ETHANOL PRODUCTION OF THE HILLTOPCOCO PRODUCTS ENTERPRISES

PRACTICUM-TERMINAL REPORT

CORADO, William L.GALONO, Domingo V.

Practicum-terminal submitted in partial fulfillment of the requirement for graduation for the degree of Agricultural Engineering Technology University of Eastern Philippines, College of Engineering, Research Contribution No._____ prepared at the University of Eastern Philippines, University Town, Northern Samar under the supervision of Engr. Lidany Fi Cornillez from December 2011 to February 2012.

March 2012

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TABLE OF CONTENTS

Acknowledgment

I. Introduction 1

Rationale 1

Importance of the Practicum 1

Objective of the Practicum 2

Time and Place of the Practicum 2

II. Host Profile 4

Organizational Set up 4

Products 6

Plant Layout 7

III Practicum – Program Activities 8

Significant Learning and Insights Skills and

Knowledge Obtained

-coco ethanol production process

9

IV Significant Insights 13

V Problems Encountered and Recommendation

Related to the Practicum

23

Appendices

Pictorials