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The Fuel Dice

▐ Introduction and Outlook▐ As of January 2015

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The Question

▐ Is it possible to have a biodiesel refinery containing the entire process from vegetable oil extraction to the ready product?

▐ Is it possible to have it self sustaining without the need of external energy?

▐ Is it possible to employ the most efficient way in producing biodiesel, a continuous process?

▐ Is it possible to produce biodiesel in a zero waste process?

▐ And all this in one single container producing up to 3,000 litres of biodiesel a day?

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We have a solution

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The Fuel Dice

The Fuel Dice

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The Fuel Dice, a complete refinery in a Dice

Bio-Diesel ProcessingBio-Diesel ProcessingCrude Oil TreatmentCrude Oil Treatment

Pure Bio-Diesel Pure Bio-Diesel

Nutrali- sation Nutrali- sation Filtration Filtration Transesteri-

fication Transesteri- fication Deguming Deguming Filtration FiltrationOil

ExpellingOil Expelling

SodiumMethylate

Acid

Oil-bearing feedstock Solid fuel

briquettes, orFertilizer

CrudeGlycerin

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▐ The challenge was to shrink a complete large scale bio diesel refinery and oil mill into almost the size of a 10’’ container and to incorporate a highly efficient process to produce biodiesel from any oil bearing feedstock according to international quality norms.

▐ Therefore the Fuel Dice is a fully equipped mini refinery mapping the complete process from oil production, oil treatment, transesterification, excessive methanol recovery, PH levelling and final purification of the bio diesel.

▐ The required power supply and process heat demand is realised by an integrated genset.

Multiple unique innovation were created which result in a patent held by Enerdice like:

▐ The specific multistage reactor

▐ The combination vessel to achieve different equivalent residence times of different liquids in one vessel

The Fuel Dice, the challenge

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▐ Compact Biodiesel production unit for Biodiesel in accordance with B100 / EN 14.214

▐ Full production process from feedstock to the highest quality ready-to-use biodiesel

▐ Contains oil expelling, degumming, transesterification, purification systems

▐ Annually production capacity around 700,000 liters,daily capacity 2,500 - 3,000 liters

▐ Can be operated with any oil-bearing feedstock

▐ Fully automated and continuous production process, no batch production

▐ Self sustaining system; Electronic production control system; Remote production supervision

▐ Size of almost a 10’’ Standard Container, weight around 4 tons

The Fuel Dice at a Glance (1)

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The process is divided into 2 blocks:

▐ Block I contains the oil extraction and oil purification.

For Waste Vegetable Oil applications, an ion exchange resin purification

filtration system is integrated.

▐ Block II the transesterifaction, methanol recovery, the bio diesel purification as well as the ion exchange resin regeneration. Block II stays identical for any oil bearing feedstock and Waste Vegetable Oil application.

The Fuel Dice at a Glance (2)

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The Main Frame – High Strength:

▐ The main frame is designed out of high strength Bosch Rexroth aluminium extrusion profiles with the same mechanical properties like equivalent steel structures, yet 30 % lighter

The Genset – Three in One

▐ The inbuilt genset is specifically designed, containing a Deutz Diesel Engine and a Leroy Somer Alternator. The B100 approved Deutz engine drives the alternator, but also delivers the necessary process heat through the use of its cooling water and runs the hydraulic system by means of a hydraulic pump mounted on a power take off

The Fuel Dice, assorted technical Details (1)

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The Expeller – High Efficiency:

▐ The expeller, a German designed and manufactured device, is driven by a radial piston hydraulic motor from Parker Hanifin (USA) and delivers an efficiency up to 94%

The Flash Tank – Nothing left over

▐ The Flash Tank, in combination with a vacuum system, extracts the entire excessive methanol from the produced biodiesel and feeds it back into the process circle

The Reactor – High Yield

▐ The 5 chamber two stage Reactor, the heart of biodiesel production, has an efficiency of approx 98%, guaranteed through its design and the use of high performance coalescers

The Fuel Dice, assorted technical Details (2)

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The Fuel Dice, assorted technical Details (3)

The Centrifuge – Removal of solid impurities guaranteed

▐ The high efficient Centrifuge from Alfa Laval (Sweden) guarantees the separation of solid impurities and residual water from the pre refined oil before entering the reactor

The Piping System – Complexity under Control

▐ The piping system and fittings are made from stainless steel Selenoid valves, sensors and pumps are ex proofed

The Control System – The brain of the Fuel Dice:

▐ All process algorithms are controlled by a Siemens S7 plc. Different pump speeds are realized by Siemens frequency inverters. The interaction of all control components is accessible through the Siemens Simatic Touch Screen Panel, displaying all relevant process information at a glance

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The Fuel Dice, Development Partners

Chemical Process Design and Assessment

Oil Expelling System

Oil Purification System

Biodiesel Purification System

Power Generation

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▐ In the developing world, and in tropical climates, Biodiesel is produced from high-yielding oil bearing fruits such as Jatropha, Palm Kernel, Copra, Sunflower Kernel and Macademia nuts to name a few.

▐ In the developed markets of North America, Australia and Europe soyabean, corn and canola are the common sources along with other raw vegetable oils (RVO's) and animal fats including restaurant trap grease.

▐ The Fuel Dice can handle most of the common feedstock without any, or only slight modifications of the expeller set up

The Fuel Dice, Feedstock

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During the production of Biodiesel the Fuel Dice automatically produces by-products such as:

▐ Crude Glycerin with a purity of ≥ 80%

Raw glycerine represents a further added value. Depending on the world market price it sells for as high as 350 USD per metric ton. The Fuel Dice produces approximately 500 kg per day. Glycerin in its purified version, is mainly used in cosmetics, oral care products or in the food industry .

▐ Press cake from the oil expelling process

The press cake is a further valuable by-product. It is used in food mills, as fertilizer or as solid fuel. Usually 1 kg of e.g. press cake from copra sells for 20 cents

The Fuel Dice, By-Products

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The Fuel Dice, Production Cost Schematic

0

5

10

15

20

25

30

35

40

45

50

55

feedstock cost

cost of consu-mables

cost of investment

overhead & logistics

cost for internal fuel consump- tion

revenues by products

net cost biodiesel

25.51

6.69

2.94

1.76

1.85

9.25

30.50

Production Costing Schematic for copra in PhP per liter and cost of copra @ 17 PhP per kg

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The Fuel Dice, Production Cost Schematic

0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

2.2

feedstock cost

cost of consu-mables

cost of investment

overhead & logistics

cost for internal fuel consump- tion

revenues by products

net cost biodiesel

0.61

0.19

0.10

0.27

0.10

1.16

Production Costing Schematic for canola in AUD per liter and cost of canola seeds @ 230 AUD per metric ton

-0.11

Revenues of press cake not considered

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The Fuel Dice, single operation layout in meters

Fuel Dice

GlycerinSodium

MethylateRecovered Methanol

Fresh Methanol

Biodiesel

8.00

7.00

Workbench and Analysing Spare Part Rack

Feedstock inBiodiesel out

Basic Requirements:

▐ Simple concrete slab

▐ Roof

▐ Fence or brick wall

▐ Lockable

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The Fuel Dice, competitive advantages

Low Cost, Fast Return on Investment for Operator

▐The cost of investment for the fuel dice makes biodiesel processing commercially viable for communities and independent enterprises.

Geographical and Operational Flexibility

▐ Compact size, stand alone set-up, and little infrastructure requirements allows for mobility of unit

▐ Easy to operate, easy to maintain

Feedstock

▐ Engineered to use a variety of feedstock (Copra, Jatropha, Palm Kernel, Canola, etc.)

Time to Market

▐ Production capacity within weeks

▐ Unit already fully operational upon delivery

Scalability

▐ Regional production networks

▐ Centralized production network

▐ Multi-million liters production capacity within weeks

High Tech, High Yield

▐ Industrial processes with yield similar or better than large refineries

An Affordable Solution Industrial Production on Short Term

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Decentralized production of Biodiesel

For large farms and cooperatives to run agricultural equipment on the produced biodiesel

The Fuel Dice, application examples

Commercial production of biodiesel to be sold to blending facilities. New government regulation in multiple countries to blend conventional fossil diesel with biodiesel increases the demand of biodiesel and constitutes a highly profitable business perspective.

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Decentralized production of Biodiesel and generation of power.

The Biodiesel produced by the Fueldice is sufficient to run a genset to produce electrical power of up to 500KVA

On remote islands, with sufficient feedstock available, the FuelDice, in combintion with an external genset, can supply electricity for up to 500 households and enough biodiesel to run vehicles or any other diesel engine (e.g. pumps, etc)

The Fuel Dice +, application examples

On large farms, together with an external genset the produced biodiesel can be used to run the agricultural equipment and to deliver the required electricity to power up the farm facilities

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Power Production in combination with a back end Biomass Power Plant

Within a zero waste concept, utilising the entire plant material of the input feedstock, the Fueldice in combination with a back end Bio Mass Power Plant can produce up to 1MW of electricity, depending on the feedstock

The Fuel Dice +, application examples

Woody Parts

Shell

Husks

Press Cake

Copra

16 tons per day

5 tons per day

Electricity

400 KW

Electricity

500 KW

Combined Process based on Coconut as feedstock

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Power Production in combination with a back end Biomass Power Plant and Coco Water Processing Facility

Within this concept the input feedstock for both, the Fuel Dice and the Biomass Power Plant, is subsidised by utilising the Coconut Water as a further highly valuable product.

The excessive heat from the genset exhaust gases as well as from the Biomass Power Plant is used to create the necessary cold for the Coco Nut Water Processing Plant through absorption chillers and to provide the heat for the dryer in order to remove the residual moisture of the feedstock for the Fuel Dices and the Biomass Power Plants

The Fuel Dice +, application examples

Coco Nut Water Plant

Bio Diesel Power Plant

Biomass Power Plant

Enerdice 10 MW combined Coco Water – Biodiesel – Biomass Power Plant

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Future Outlook and Development Program

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FuelDice

MT 3

FuelDice

MT 4

FuelDice

MT 10

WVODice

MT 4

PuelDice+

500

WVODice+

500

FuelDice+

1000

End Product Biodiesel Biodiesel Biodiesel Biodiesel Power Power Biodiesel & Power

Feedstock Any oil bearing feedstock

Any oil bearing feedstock

Any vegetable oil

Any waste vegetable oil

Any oil bearing feedstock

Any waste vegetable oil

Any oil bearing feedstock + any biomass

Capacity (gross/day)

Up to 3000litres

Up to 4000litres

Up to 10000litres

Up to 4000 litres

Up to 500 KW

Up to 500 KW

Up to 1 MW

Technology FuelDice FuelDice FuelDice in an upscaled version

FuelDice with specific oil purification system

FuelDice with independent genset

WVO Dice with independent genset

Combi-nation of 1 FuelDice & 1 Biomass Plant

Oil Extraction integrated Integrated external none integrated none integrated

Status Show unit Projected for 2015

Projected for 2015

Median stage of design

Projected for 2015

Median stage of design

Projected for 2015

For further inquiries: info@enerdice.com