Process & Technology Infographic
Full technical schematic, unit operations, and process architecture.
Comprehensive Plant Engineering & Technology Architecture
MAHIJA is a pioneer in turnkey B100 Biodiesel plants compliant with IS 15607:2022, ASTM D6751, and EN 14214 standards. Our proprietary multi-feedstock technology seamlessly handles high FFA (up to 40% FFA) Used Cooking Oil (UCO), tallow, palm stearin, and acid oils. Featuring acid pre-esterification, two-stage alkaline transesterification, dry/wet purification, and vacuum methanol recovery, our plants deliver >98% theoretical ester conversion.
Key Process Stages & Methodology
Integrated continuous engineering flow from raw feedstock preparation to final finished product output.
Feedstock Pretreatment & Acid Esterification
Removal of gums, solids, moisture and catalytic reduction of FFA from 40% down to <1%.
Two-Stage Continuous Transesterification
Optimized methoxide reaction converting triglycerides into methyl esters and crude glycerin.
Methanol Rectification Column
Multi-stage distillation column recovering dry methanol for continuous loop recycling.
Ester Washing & Ion-Exchange Polishing
Dry resin beds or continuous centrifugal water wash removing trace soap, catalyst, and glycerol.
Engineered System Capabilities
Design Specifications & Performance Guarantees
| Parameter / Metric | Engineering Benchmark & Value |
|---|---|
| Plant Capacity | 2 TPD to 500 TPD (10 KLPD – 150 KLPD) |
| Ester Content (Purity) | ≥ 99.0% (Standard requires ≥ 96.5%) |
| Conversion Yield | > 98.5% on Triglyceride Basis |
| Flash Point | ≥ 130°C (IS 15607 Compliant) |
| Total Glycerin | ≤ 0.20% Mass |
| Standards Compliance | IS 15607:2022, ASTM D6751, EN 14214, BIS Certified |
Compatible Feedstocks & Industrial Outputs
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Explore All 9 Turnkey Engineering Facilities
Solvent Extraction Systems & Technology
Complete turnkey solvent extraction plants engineered for maximum oil recovery with minimum solvent loss and lowest utility consumption.
Chemical & Edible Oil Refining Plants
Multi-feedstock continuous and batch refining lines for vegetable, seed, and tree-borne oils delivering exceptional clarity and minimal oil loss.
Oleochemical Engineering & Processing
Advanced high-pressure thermal splitting and distillation technologies converting natural fats and oils into high-purity fatty acids and refined glycerin.
Fat Modification & Fractionation Plants
Specialized plants for tailoring fat properties and fatty acid compositions to produce trans-free specialty fats, olein, stearin, and structured lipids.
Specialty Fats & Value-Added Processing
Engineered systems for the production of high-margin value-added derivatives from refining gums, fats, and confectionery lipid bases.
Turnkey Biodiesel Manufacturing Plants
State-of-the-art B100 biodiesel plants capable of processing high-FFA feedstocks, Used Cooking Oil, animal fats, and acid oils with >98% yield.
Bioethanol & Compressed Biogas (CBG) Plants
Turnkey grain-based distilleries with zero liquid discharge (ZLD), molecular sieve dehydration (MSDH), and CSTR anaerobic digester systems.
Custom-Engineered & Tailor-Made Equipment
In-house fabrication facilities certified for ASME, TEMA, and IS code compliance, manufacturing critical process equipment and skids.
In-House R&D & Pilot-Scale Validation
Dedicated research laboratories and pilot plant facilities to analyze customer feedstocks, validate custom process parameters, and optimize product yields.