Project Guidelines

Biofuel Understanding

Comprehensive conversion metrics, plant utilities, CAPEX guide, and project economics for setting up Biodiesel, Bioethanol, and Compressed Biogas (CBG) installations.

Yield Calculator

Interactive Yield & CAPEX Estimator

Input project parameters to calculate technical outputs and utility requirements immediately.

Daily Production
Annual Production
Valuable By-products
Estimated CAPEX (CAPEX)
Land Required
Power Load
Boiler / Steam
Water Requirement
Typical Payback ROI
Biodiesel B100 Plants

Semi-Continuous PLC Based Multi-Feedstock Plants

MAHIJA designs and installs high-efficiency, multi-feedstock biodiesel production systems complying fully with BIS and ASTM specifications. The plants are capable of handling high FFA oils and feedstocks seamlessly.

Biodiesel Plant
Low Investment
Starts from ₹5 Crore onwards
Multi-Feedstock
UCO, PFAD, Acid Oil, MFA, Animal Fats
High Quality
BIS Standard B100 Production
PLC Automation
Semi-continuous PLC based operation

Plant Specifications Table

Particulars 10 KLPD 20 KLPD 30 KLPD 40 KLPD 50 KLPD
Production Capacity 10 KLPD 20 KLPD 30 KLPD 40 KLPD 50 KLPD
Feedstock UCO, PFAD, Acid Oil, MFA, High FFA Oils (Up to 95% FFA with Esterification)
Technology Semi-Continuous PLC Based
Land Requirement 1 Acre 1.5 Acre 2 Acre 2.5 Acre 3 Acre
Built-Up Area 12,000 Sq.ft 18,000 Sq.ft 25,000 Sq.ft 32,000 Sq.ft 40,000 Sq.ft
Connected Power Load 100 KW 100 KW 100 KW 250 KW 300 KW
Boiler Requirement 1 TPH 2 TPH 3 TPH 4 TPH 5 TPH
Water Requirement 10 - 15 KLD 20 - 25 KLD 30 - 35 KLD 40 - 45 KLD 50 - 60 KLD
Manpower Requirement 10 - 12 15 - 18 20 - 25 25 - 35 40 - 45
Plant Operation 24 Hours Operation

Wide Feedstocks Accepted

Used Cooking Oil (UCO)
PFAD (Palm Fatty Acid Distillate)
Acid Oil
Mixed Fatty Acid (MFA)
Animal Tallow
Chicken Fat
Fish Oil
Vegetable Oil Sludge
Soap Stock Oil

Complete Turnkey Solutions (Concept to Commissioning)

1
Feasibility & Consulting

Capacity selection, feedstock assessment, financial viability studies, planning.

2
Process Design & Eng.

Process Flow Diagrams (PFD), P&ID development, utilities and equipment engineering.

3
Manufacturing & Supply

Reactors, distillation systems, methanol recovery units, storage tanks.

4
Erection & Commissioning

Site supervision, installation support, trial runs, performance audits.

5
Operation & Training

Operator training, SOP development, troubleshooting support, yield audits.

6
Feedstock Sourcing

UCO procurement network, acid oil sourcing and multi-feedstock strategy.

7
Quality & BIS Support

Product standardization, lab setup guidance, BIS standard compliance.

8
Market & Export Support

Buyer network access, sales strategy, export market guidance.

Project Investment (CAPEX) & ROI Guide

Capacity Estimated Investment (CAPEX)* Typical Payback Period*
10 KLPD ₹ 5 Crore Onwards 3 - 4 Years
20 KLPD ₹ 9 Crore Onwards 3 - 4 Years
30 KLPD ₹ 13 Crore Onwards 2.5 - 4 Years
40 KLPD ₹ 17 Crore Onwards 2.5 - 3.5 Years
50 KLPD ₹ 21 Crore Onwards 2.5 - 3.5 Years

*Note: CAPEX calculations relate to the basic semi-continuous plant. Land, statutory approvals, working capital, and optional automation features are excluded. Payback calculations are subject to raw material feedstock cost and plant operating efficiency.

Complete Biodiesel Production Process Flowchart (Oils & Waste)

Biodiesel Production Process Flowchart
Fuel Grade Bioethanol

Grain-Based Feedstock to Ethanol Conversion Guide

Multi-feedstock grain-based bioethanol plants support broken rice, corn (maize), jowar, sweet sorghum, and damaged food grains to yield 99.8% fuel-grade anhydrous ethanol, aligned with India's National Biofuel Policy.

Bioethanol Plant
Corn / Jowar (60% Starch) 380 Litres Ethanol per 1 MT Grain (1L ≈ 2.65 kg Grain)
Broken Rice (72% Starch) 425 - 430 Litres Ethanol per 1 MT Rice (1L ≈ 2.33 kg Rice)

Daily Feedstock Feed Requirements

Plant Capacity Corn / Jowar Feedstock (60% Starch) Broken Rice Feedstock (72% Starch)
Ethanol Output Grain Feed (MT/Day) Ethanol Output Rice Feed (MT/Day)
10 KLPD 10,000 L/Day 26.5 MT 10,000 L/Day 23 MT
20 KLPD 20,000 L/Day 53.0 MT 20,000 L/Day 47 MT
30 KLPD 30,000 L/Day 80.0 MT 30,000 L/Day 70 MT
40 KLPD 40,000 L/Day 106.0 MT 40,000 L/Day 94 MT
50 KLPD 50,000 L/Day 132.0 MT 50,000 L/Day 117 MT

CAPEX, Land & Utilities Specifications Table

Capacity Investment CAPEX Land Required Power Connected Steam Boiler Water (KLD) Manpower Typical Payback
10 KLPD ₹ 12 - 15 Cr 2 - 3 Acres 400 KW 6 TPH 120 - 150 20 - 25 4 - 6 Years
20 KLPD ₹ 20 - 25 Cr 3 - 4 Acres 650 KW 10 TPH 250 - 300 30 - 35 4 - 6 Years
30 KLPD ₹ 30 - 35 Cr 4 - 5 Acres 900 KW 15 TPH 350 - 450 40 - 50 3.5 - 5 Years
40 KLPD ₹ 40 - 50 Cr 5 - 6 Acres 1,200 KW 20 TPH 500 - 600 55 - 65 3 - 5 Years
50 KLPD ₹ 50 - 65 Cr 6 - 8 Acres 1,500 KW 25 TPH 650 - 800 70 - 80 3 - 4.5 Years

Key Investment Advantages

  • Govt support: Direct off-take security under the national Ethanol Blending Programme (EBP) mandates.
  • Flexibility: Process grains, broken rice, sorghum, or maize in the same plant depending on seasonal prices.
  • By-product economics: Sale of DDGS (animal feed) and CO₂ offsets operational costs substantially.

By-Product Valuation

DDGS
Distillers Dried Grains with Solubles

High-protein animal feed by-product that commands a strong premium in local dairy and poultry industries.

CO₂
Carbon Dioxide Recovery

Recovered fermentation gases purified to food-grade standards for beverage and industrial markets.

Industrial Bioethanol Production Process Flowchart

Bioethanol Production Process Flowchart
Compressed Biogas (CBG)

Napier Grass & Cattle Dung to Bio-CNG Projects

Turnkey CBG plants employ anaerobic digestion to process Napier grass, cattle manure, press mud, and food waste into vehicle-grade renewable Bio-CNG, producing organic solid/liquid fertilizer by-products.

Compressed Biogas Plant
Napier Grass to Bio-CNG Yield
1 Ton Napier Grass → Up to 50 kg Bio-CNG
Highly productive multi-cut grass feedstock

CBG Project Capacity Specifications Table

CBG Capacity Napier Grass Feed Cattle dung Feed Biogas Generated CBG Output (kg/Day) Land Requirement Project CAPEX Power connected Typical Payback
1 TPD 25 MT/Day 3 MT/Day 2,600 - 2,900 m³ 950 - 1,100 1 Acre ₹ 4 - 5 Cr 80 - 100 KW 2 - 3 Years
3 TPD 75 MT/Day 10 MT/Day 7,875 - 8,625 m³ 2,900 - 3,200 2 - 3 Acres ₹ 11 - 12 Cr 246 KW
5 TPD 125 MT/Day 18 MT/Day 13,000 - 14,000 m³ 4,800 - 5,300 4 - 5 Acres ₹ 17 - 19 Cr 425 - 450 KW
6 TPD 150 MT/Day 25 MT/Day 15,750 - 17,250 m³ 5,800 - 6,400 5 - 6 Acres ₹ 21 - 22 Cr 532 KW

FOM & LFOM Production Capacities

CBG Capacity FOM Solid (TPD) LFOM Liquid (KLPD)
1 TPD 5 - 7 TPD 15 - 20 KLPD
3 TPD 15 - 20 TPD 45 - 50 KLPD
5 TPD 25 - 28 TPD 75 - 80 KLPD
6 TPD 30 TPD 90 - 95 KLPD

Organic Fertilizers (By-Products)

Anaerobic digestion produces premium organic bio-fertilizers. These residues are packed with plant nutrients and trace minerals, serving as a significant source of additional revenue for the project.

FOM
Fermented Organic Manure (Solid) Rich in organic carbon and humus. Excellent soil builder.
LFOM
Liquid Fermented Organic Manure (Liquid) Rapid action liquid fertilizer ideal for drip irrigation.

Complete Bio-CNG Production Process Flowchart

Bio-CNG Production Process Flowchart