The work is aimed at conversion of non-edible jatropha curcas de-oiled seed cake (the residue left after extraction of oil from the seed) into bio-oil and bio-char through pyrolysis process. A fluidized bed pyrolysis system with maximum feed rate of 12 g/min was designed and fabricated. The particle size range, sweep gas flow rate and operating temperature were optimized as 0.5 mm-0.99 mm, 8 L/min and 450 degrees C respectively for obtaining maximum yield of bio-oil (48%) and bio-char (35.1%). The crude bio-oil has lower viscosity (1.98 cSt), higher moisture content (31%) and higher density (1040 kg/m(3)) as compared to commercial petro-diesel. The crude bio-oil was upgraded to make it suitable for engine application. The moisture content of the crude bio-oil was removed about 3% by weight using Na2SO4 as a reagent. The heavier fractions, tar, moisture and inorganic materials were removed from the crude oil by distillation in the temperature range of 40 degrees C-80 degrees C. The density, viscosity and moisture content of the upgraded bio-oil decreased to 1030 kg/m(3), 1.77 cSt and 25% respectively. (C) 2013 Elsevier Ltd. All rights reserved.