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Small-Scale Biodiesel Production

Small-Scale Biodiesel Production Energy Overview Where does our energy come from? 85% from fossil fuels coal, crude oil products, natural gas 7% renewable fuels hydro power, wind, solar, biomass, biofuels 8% nuclear Energy Use What do we use energy for? Heating & Cooling

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Small-Scale Biodiesel Production

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  1. Small-Scale Biodiesel Production

  2. Energy Overview Where does our energy come from? 85% from fossil fuels coal, crude oil products, natural gas 7% renewable fuels hydro power, wind, solar, biomass, biofuels 8% nuclear

  3. Energy Use What do we use energy for? Heating & Cooling Lights, appliances, cooking, household uses Manufacturing Transportation

  4. Transportation Fuels Two fuels dominate the transportation fuel market: Diesel Biodiesel can be used to supplement or replace diesel fuel Gasoline

  5. Diesel Fuel Facts Diesel Fuel Facts Widely available Diesel engines are common Refining and transportation infrastructure is well developed Consumers know about diesel

  6. Diesel Fuel Recent Developments New diesel fuel standards (low sulfur diesel) New diesel burns cleaner (good) Lubricity is reduced (bad) Retail diesel prices have increased Why? Demand has been growing Refining capacity is strained Transportation capacity is strained Higher fuel quality standards

  7. Diesel Fuel

  8. Diesel Fuel

  9. Biodiesel Facts What is biodiesel? Fuel created from vegetable oil or animal fat Small-scale producers generally use vegetable oil Can be used in traditional diesel engines Biodiesel can be blended with diesel fuel Biodiesel be produced in small or large quantities

  10. Biodiesel Facts Lower energy content than Diesel Biodiesel: 118,296 BTUs per gallon No. 2 Diesel: 129,500 BTUs per gallon Source: National Biodiesel Board Energy Lifecycle 3.2 units of energy are produced for each energy unit used Source: NREL

  11. Biodiesel Facts What type of oil is most biodiesel made from? Soybean oil in the USA Rapeseed oil in Europe Is biodiesel the same as vegetable oil? No!

  12. Biodiesel Will biodiesel damage my engine? No…if the biodiesel meets the standards of ASTM 6751 One exception: Biodiesel can damage certain natural rubber engine components over time Older engines may require the replacement of fuel lines and some gaskets These components are unlikely to fail immediately but may fail with increased biodiesel use

  13. Biodiesel

  14. Biodiesel Price Data from Clean Cities Alternative Fuel Price Report (DOE)

  15. SVO and WVO Straight Vegetable Oil is not biodiesel This includes Waste Vegetable Oil Diesel engines can be modified to run on vegetable oil Some users who have modified engines have reported long term problems using SVO

  16. SVO and WVO Main Problems: These fuels are too thick. The must be thinned to function in a diesel engine How? By heating or a by chemical reaction (the chemical reaction is the biodiesel production) Problem is worse the lower the temperature Modified engines still typically use SVO in conjunction with diesel for start up and shut down No government incentives for SVO and WVO

  17. Oilseeds and Oilseed Processing

  18. Types of Oilseeds Major U.S. Oilseed Crops Soybean Cottonseed Sunflower • Canola/Rapeseed • Flaxseed • Safflower

  19. Types of Oilseeds Other oil producing crops Corn Peanut Camelina • Palm • Olive • Coconut

  20. Oilseed Crops: 2007 Yields Crop Ave. Yield Ave. Oil Content Soybeans 41.7 bu/acre ≈ 22% Canola 1,250 lbs/acre ≈ 40% Flaxseed 16.9 bu/acre ≈ 38% Safflower 1,215 lbs/acre ≈ 35% Sunflower 1,436 lbs/acre ≈ 42% Mustard 603 lbs/acre ≈ 36%

  21. Oilseed Processing The Oilseed Processing Industry: Separates the “whole seed” into 2 or more products The difference between the cost of the seed and the value of the products created is the “crushing margin”

  22. Processing Technology Two General Methods Solvent Extraction Standard technology for facilities with daily capacities of greater than 300 tons per day Commonly used in conjunction with some form of mechanical extraction Mechanical Extraction Typically used for facilities with daily capacities of less than 150 tons per day

  23. Solvent Extraction Nearly all commercial soybean processors use solvent extraction technology

  24. Solvent Extraction The basic process: Seed Preparation Removal of foreign objects Removal of seed hulls or shells for some seeds Pre-Pressing Seed is crushed through a mechanical press Pre-Pressing removes some oil from high oil content seeds

  25. Solvent Extraction The basic process: Solvent Application Solvent is applied to the pre-pressed material The solvent bonds to the oil in the material Solvent & oil mixture is removed from the meal The oil is then separated from the solvent which is reused in the process

  26. Solvent Extraction Benefits: Solvent Extraction is capable of recovering of 99% of the oil contained in the seed Lowest cost per ton for commercial processing Challenges: Large capital investment Not feasible for small-scale processing Environmental concerns

  27. Mechanical Extraction The basic process: Seed Preparation Removal of foreign objects Removal of seed hulls or shells for some seeds Extraction Seed is processed by a mechanical press Removing 65-80% of oil contained in the seed

  28. Mechanical Extraction Required Equipment Mechanical Press Power source for the press Seed Bins Meal Bins Oil Tanks Pumps, Filters, Plumbing

  29. Example On-Farm Example: If you plant 100 acres of canola, with an average yield of 1,100 lbs per acre, your production is approximately 55 tons

  30. Example The 55 tons of seed will yield approximately: 4,200 gallons of oil 36 tons of meal * Assuming: The seed has 38% oil content and press recovers 75% of the oil content in the seed.

  31. Example On-Farm Example: If you plant 100 acres of safflower, with an average yield of 800 lbs per acre, your production is approximately 40 tons

  32. Example The 40 tons of seed will yield approximately: 2,800 gallons of oil 27 tons of meal * Assuming: The seed has 35% oil content and press recovers 75% of the oil content in the seed.

  33. Biodiesel Production Technology

  34. Biodiesel Process Basic Overview Inputs: Oil, Alcohol & Catalyst Outputs: Biodiesel & Crude Glycerin

  35. Biodiesel Process Sample Recipe Oil 100 Parts Alcohol 10 to 20 Parts Catalyst 0.5 to 3 Parts * Manufacturers often provide a “basic” recipe to use as a starting point.

  36. Biodiesel Process Outputs Biodiesel 100 Parts Crude Glycerin 10-20 Parts

  37. Biodiesel Process Pre-Reaction Equipment Oil Storage Tank Alcohol Storage Tank Catalyst Storage Biodiesel “Reactor” Pumps, Filters, Plumbing

  38. Biodiesel Process Post-Reaction Equipment Settling tanks and/or Separating Equipment Washing Equipment Drying Equipment Biodiesel Storage Tank Glycerin Storage Tank Pumps, Filters, Plumbing

  39. Biodiesel Process Biodiesel Equipment Micro Scale Processors 100 gallons or less per batch Numerous Manufacturers Some sold as “kits” Others sold as “ready to use” Accessories included in the package varies

  40. Biodiesel Process Micro Scale Biodiesel Processor

  41. Biodiesel Process Biodiesel Equipment Small-Scale Processors 75 to 300 gallons per batch Fewer Manufacturers Usually not sold as “kits” Typically higher quality materials Accessories included in the package varies

  42. Biodiesel Process Small-Scale Biodiesel Processor

  43. Biodiesel Process Processing 4,200 Gallons 40 gallon processor: 105 batches 60 gallon processor: 70 batches 100 gallon processor: 42 batches

  44. Final Products Biodiesel On-Farm Use Blended Fuels Fuel Quality Important Vehicle Modifications May need to replace natural rubber fuel lines and gaskets

  45. Final Products Crude Glycerin No Ready Market for Crude Glycerin Quantity produced is 10% to 20% of biodiesel production Contains Methanol & Catalyst Possible Uses: Compost Fuel Oil Refine to Pharmaceutical Grade Glycerin

  46. Government Involvement:Regulations, Incentives & Policies

  47. Federal Policy What agency is responsible for biofuel policy? A) Energy B) Agriculture C) Commerce D) Environmental Protection E) Transportation Answer: All of the above

  48. Biofuels Policy Current federal policy for biofuels: Most of the biofuels policy is: Farm Energy Energy Policy Other agency are involved: U.S. Dept. of Transportation Environmental Protection Agency Internal Revenue Service Department of Labor

  49. Key Federal Policies Biodiesel Incentives Biodiesel Blenders Tax Credit $1.00 per gallon for virgin oils $0.50 per gallon for recycled oils Small Producer Tax Credit $0.10 per gallon of Ethanol or Biodiesel

  50. State Programs & Regulations Each state has different regulations and incentives for biodiesel. Check with your state officials for details You may need to check with Departments of Agriculture, Commerce, Environmental Protection, Transportation, and/or other departments

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