Embed Size (px)
Citation preview
BiodieselProcessAnalysisforEPOCA
AnInteractiveQualifyingProjectReport
SubmittedtotheFaculty
Ofthe
WORCESTERPOLYTECHNICINSTITUTE
Inpartialrequirementsforthe
DegreeofBachelorofScience
By
________________________________________
NikolasAlbergariaDavidAverill
________________________________________
PatrickFraserMichaelSangenario
Submitted:3/5/2009
_________________________________
ProfessorRobertKrueger,MajorAdvisor
_________________________________
ProfessorRichardVaz,Co‐Advisor
i
Abstract
Thisreport,commissionedbythenon‐profitcompanyEPOCA,investigatesbiodieselproduction
processesforastart‐upenterprise.Differentprocesseswereanalyzedbasedonoutsideresearch
conducted.TheprocesseswerethenratedusingcriteriagivenbyEPOCA.Basedonthatrating,a
recommendedprocesswasthenselectedforEPOCAtopursueandimplementintheirEmpower
initiativeinordertomeettheirproductionneedsandcreateasuccessfulgreencompany.
ii
Acknowledgements
WewouldliketothankoursponsorsEPOCAforgivingusetheopportunitytoassistintheir
effortsatbetteringthecityofWorcester.WewouldespeciallyliketothankSarahAssefaandJuanOtero
fortheguidancetheyprovidedusduringthisproject.
WewouldliketothankMr.BruceFieneofWPIforhelpingusgetanunderstandingofthe
collection,transportandfilteringofWVO.WealsowanttothankthemenatSteve’sAutoBodyfor
providinggreatrealworldinformationandexamples,MarkTrianoforgoingaboveandbeyondinthe
helpingofEPOCA,andalltheotherEPOCAmemberswhohavegivenustheirhelp.
WealsowanttoacknowledgetheMarketingteamandtheiradvisorProf.Millerforallthegreat
worktheydidandforhelpingbothusandEPOCA.
Finally,wewanttogivethankstoouradvisorRobKruegerfortheassistance,guidanceand
friendshipthatwereceivedfromhimoverthecourseoftheentireIQPproject.
iii
TableofContents
Abstract i Acknowledgements iiTableofContents iiiListofFigures ivReferences 34Appendix 37Chapter1:Introduction 1
1.1 ProblemStatement 11.2 GoalsandObjectives 11.3 Summary 2
Chapter2:Background 3 2.1EPOCA 3
2.2EnvironmentalImpacts 3 2.3BiodieselfromWasteVegetableOil:APossiblesolution? 6 2.4Collection 8 2.5Storage 8 2.6Transportation 11 2.7Production 11 2.7.1BatchProcess 11 2.7.2Ultrasonication 15 2.7.3SupercriticalMethanol 17 2.8Safety 17 2.8.1NFPASafetyratingsystem 17 2.8.2RatingoftheChemicalsUsed 19Chapter3:Methodology 21 3.1DeterminingtheImportantCriteria 21 3.2DevelopingtheOptimalProcess 21 3.3PresentingtoEPOCA 22Chapter4:Analysis 23 4.1ExplanationoftheRatingSystem 23 4.2BatchProcess 24 4.2.1Cost 25 4.2.2Upgradability 25 4.2.3Efficiency 25 4.2.4PersonnelRequirements 25 4.3ContinuousBatchProcess 27 4.3.1Cost 27 4.3.2Upgradability 27 4.3.3Efficiency 27 4.3.4PersonnelRequirements 28 4.4Ultrasonication 30 4.4.1Cost 30 4.4.2Upgradability 30
iv
4.4.3Efficiency 30 4.4.4PersonnelRequirements 31
Chapter5:ConclusionandRecommendations 33
ListofTablesandFiguresFigure1:SmallStoragetanksandpumpstomoveWVO,Hubbardston,MA 10Figure1:BatchProcessComponents,Hubbardston,MASite 12Figure2:Schematicofabatchprocess 13Figure2:Schematicofanultrasonicprocess 16Figure3:ExampleofaNFPAratingsystem 18 Table1:BatchProcessRatingChart 26Table2:ContinuousBatchProcessRatingChart 29Table3:UltrasonicationRatingChart 32
1
1.0 Introduction
1.1ProblemStatement
Globalclimatechangehasbecomeamajorprobleminthelast50years.Harmfulchemicalsdamage
theozonelayerandcreateaninsulatinglayerintheatmospherethatcausesariseintemperatureand
moreaggressiveweatherpatterns.Mostoftheseharmfulchemicalsaretheresultofburningfossilfuels.
Therefore,itiscrucialthatwetakeimmediatestepstocontroltheuseoffossilfueluntilabetter,
cleaneralternativeisavailable.
1.2GoalsandObjectives
EPOCAbegantheEMPOWERinitiativetocreatejobsforex‐prisoners,whilehelpingthe
environment.EMPOWERisacooperativebusinessthatwillconvertusedcookingoilintobiodiesel.
EMPOWERwillhelpboththecommunityandtheenvironmentbycreatingmore“greencollar”jobsfor
theWorcestercommunity.Bycreatingnewenvironmentallyfriendlyjobs,EMPOWERcanemploy
regularpeopleandintroducethemtoamorehigh‐techindustry.Greentechnologyisarapidlygrowing
areaandhasmuchpotentialforsteadygrowthinthefuture.Thesejobswillhelpensurethat
Massachusettsremainsanenvironmentallyfriendlytechnologyleaderwhileworkingtocreateacleaner
tomorrowforfuturegenerations.
ThegoalofthisprojectwastodesignandconstructapilotplantforEPOCAcapableofproducing
approximately320gallonsofbiodieselperdayandbeabletosupport2full‐timeemployees.Our
researchshowsthatEPOCAcanmeetthesegoalsandmore.WhileEPOCAhadsomeunderstandingof
thebiodieselconversionprocess,weprovidedthemagreaterknowledgeofthesystemdynamicsthan
theycouldhaveattainedontheirown.AfterourresearchwascompleteditwasuptoEPOCAtodecide
whatsuitedthembest.Though,withlittlealterations,EPOCA’sfinalsystemdesignwillbesimilartothat
whichweanalyzedandsuggested.Intheend,ourprojecthasaccomplishedwhatitwassetouttodo.
Thefinalsystemwillbeabletoproduceinexcessof320gallonsperdayandsustain2full‐time
employees.
2
1.3Summary
Thefollowingchaptersincludeadetaileddescriptionoftheproject.Thesechaptersincludethe
background,methodology,analysisandconclusion.Firstthebackgroundwilldescribethecompany
EPOCAandresearchdonetowardstheproject,startingwithenvironmentalimpacts,historyon
biodiesel,andendingwithprocessesandlogisticstoproducebiodiesel.Followingthebackgroundisthe
methodologychapter.Inthischapterthestepsforaccomplishingthegoalsofthisprojectareoutlined,
fromdeterminingthecriteriafortheprojecttohowtoselectanoptimalsystemforEPOCA.Thenext
chapteristheanalysisincludestheresultsoftheproject.Intheanalysis,eachprocessforproducing
biodieselisevaluatedaswellastheevaluationmatrix.Thelastchapter,theconclusion,willgiveashort
summaryoftheresultsgatheredandthesuggestionsmadetoEPOCA.
3
2.0Background
Inthischapterwewilldiscusshowrecentchangesinourenvironmenthavesparkeda
worldwidesearchforalternativeenergysources.First,wewillintroduceEPOCAandhowtheir
cooperativebiodieselinitiative,Empower,willhelpthemachievetheirlong‐termobjectives.Next,we
willdiscusstheenvironmentalimpactsassociatedwiththeuseoffossilfuelsandhowbiofuelscanhelp
minimizethoseeffects.Finally,wewillexplorethealternativeofbiodiesel;fromthecollectionofWVO,
tothestorageofmaterials,andthentothesafeproductionprocesses.
2.1E.P.O.C.A
EPOCAstandsforEx‐prisonersandPrisonersOrganizingforCommunityAdvancement.Thisisa
groupthatbelievestheycannotwaitaroundfortheworldtochange,sotheyaremobilizingtochangeit
themselves.Theirmissionstatementis:“Workingtogethertocreateresourcesandopportunitiesfor
thosewhohavepaidtheirdebttosociety.”EPOCAisinvolvedinmanythings.Oneoftheirmainprojects
isCORI(CriminalOffenderRecordInformation)reform,tryingtochangestatelawsothataCORIisnot
toorestrictivewhengettingajob.Anotherprogramisthenewleafprogram;theyworkwithjob
councilorsandemployerstohelpex‐prisonersfindemployment.
Empower,EPOCA’snewinitiative,isacooperativebusiness.Inacooperativebusinesseach
employeeholdsashareofthebusinessandhasasayinthedecision‐making.ThegoaloftheEmpower
projectistomakeafullyoperationalbiodieselmanufacturingpilotplantthatisabletoproduce
approximately320gallonsper8‐hourshift.Hopefullytheplantwillbeabletoemployseveralfulltime
employees.Empowerwillbeapilotproject,itwillbeanexperiment.Ifitbecomessuccessful,itwill
standasamoldformorebiodieselplantswithlargeroutputstobebuiltinthefuture.Thelong‐term
goalsofEmpoweraretoincreaseproductiontoacommerciallevelwhileenhancingproductqualityand
tocreateanewmarketofgreenjobs.
2.2EnvironmentalImpacts
Theearthhasgonethroughmanyclimatechangesthroughoutitshistory.Climatechangeis
definedbytheU.S.EnvironmentalProtectionAgencyas,“significantchangesinmeasuresofclimate
(suchastemperature,precipitation,orwindlastingforanextendedperiod(decadesorlonger)).”
(http://www.epa.gov)Therecentriseintemperatureandmoreaggressiveweatherpatternshavebeen
4
attributedtotheincreasinguseoffossilfuels.In1880,theaveragetemperatureoftheearthwas56.676
°Fwhilein2005thistemperatureincreasedto58.062o.(http://math.ucr.edu/home/baez/temperature)
Greenhousegases,gaseousconstituentsoftheatmospherethatabsorbandemitradiationthatare
producedasaresultoftheburningoffossilfuelshavecloggedtheearth’satmosphere,preventingheat
fromescaping.Therehasbeenawidespreadcallforanincreasedawarenessofthisproblem,withthe
hopethatmorepeoplewillconsideralternative,moreenvironmentallyfriendlyfuels.
Therearevaryingargumentsforthecauseofglobalclimatechange.Somebelievethatthe
recentchangesaresolelyattributedtotheearth’snaturalcycles,whileothersbelievethehuman
interferenceistoblame.Itislikelythatthesourceoftheproblemisacombinationofthetwo.The
earth’snaturalclimatechangeiscausedbymanyfactorsincludingsolaractivity,volcanicactivityand
Milankovitchcycles(http://www.skepticalscience.com).Adirectcorrelationbetweensolaractivityand
averageglobaltemperaturehasbeendiscovered.Ironically,thiscorrelationseemstohaveended
around1970,whichsomebelieveisastrongargumentthatshowstheimpactofCO2emissionshadon
ourrecentclimatechanges.Volcaniceruptions,orlackthereof,arealsobelievedtobeamajor
contributortotherecentvariationofclimate.VolcanoesemitCO2,whichleadstowarming,butthey
alsoemitsulfateaerosols,whichcoolstheearth.Becausevolcanoesonlyaccountforlessthan1%ofthe
earth’scarbondioxide,itisoftenconsiderednegligiblewhencomparedtoothersources.Thesulfate
aerosolshaveamoreprofoundinfluenceontheatmospherebecauseithasalongerlastingeffect.
Periodsofhighvolcanicactivitycancauseuptoa1oFdecreaseintemperature.Whentheseeffects
wearoffandtheearthbeginstowarmagain,itcanbemisconstruedaswarmingfromotherfactors.
Lastly,theearthundergoescyclicalperiodsofwarmingandcoolingknownasMilankovitchcycles.These
cyclesconsistofabout120,000yearsoficeages,separatedbyshortcyclesofwarmthknownas
interglacialperiods.Wearecurrentlyinaninterglacialperiod,whichaccountsforthewarmingthatwe
havebeenexperiencing(http://www.koshlandscience.org).
Despitealloftheargumentsfornaturalchanges,thereisoverwhelmingevidencethathuman
activityhasagreataffectontheatmosphere.Eventhoughwearepresentlyinaninterglacialperiod,
andwarmingshouldbeexpected,thepast100yearshaveshownadramaticincreaseintherateof
warming.ThisdramaticincreaseisattributedtoanincreaseofCO2productionfromtheburningoffossil
fuels.“Beginningwiththeindustrialrevolutioninthe1880’s,thehumanconsumptionoffossilfuelshas
elevatedCO2levelsfromaconcentrationofabout280ppmtoabout387ppm”(Adam,2008).Thishas
5
causedatemperatureelevationofabout1.3oF,withanexpectedincreaseofanother2‐10oFbytheend
ofthiscentury.
Themaincontributorofgreenhousegasesiscarbondioxide.WhenCO2becomestrappedinthe
atmosphereiscreatessomethingknownasthegreenhouseeffect,theformationofalayerinthe
atmospherepreventingheatfromescaping.Thiscausesasubstantialincreaseinaverageglobal
temperature.Also,theincreaseinaveragetemperaturehasamajoreffectontheearth’sweather
patterns.Thefrequencyandseverityofnaturalweatherdisasters,suchashurricanesandtornadoes,
hasgoneupgreatlybecauseoftheCO2intheatmosphere.
Carbondioxideisproducedfromavarietyofsources.CO2isabyproductthatcomesfromthe
productionofmetals,suchastitaniumandaluminum.Deforestationisalsoahugeconcerniscertain
partsoftheworld.Itisoftenoverlookedasacontributortoglobalwarming,becauseplantsandtrees
absorbCO2,cuttingthemdowngreatlyreducesthecapabilitytoremoveCO2fromtheatmosphere.
Finally,themostrelevantfactoristheCO2thatisproducedwhenfossilfuelsareburned.Fossilfuelsare
verywidelyusedinmodernsociety,frommanufacturingplantstogasolineinourcars.Theburningof
fossilfuelshascontributedthemostofthehumandamagetotheearthwithdeforestationand
urbanizationalsodealingsignificantdamage(http://www.epa.gov).Themostcommonwaythatmost
peopleburnfossilfuelsisthroughdrivingtheircars,whichaccountsforabout20%ofglobalcarbon
dioxideemissions.Thosewholiveinaharshwinterenvironment,likeWorcester,alsousesignificant
amountsofoiltoheattheirhomeinthewinter.
Carbondioxideisthehighestcontributorofgreenhousegases,butothergasessuchaswater
vapor,methaneandnitrousoxidealsocontributeharmtotheatmosphere.Methaneabsorbs25times
moreheatthanCO2,butitispresentinmuchsmalleramounts.Itisproducedfromwetlands,energy
productionandlivestock,whichaccountsformorethan50%oftotalmethaneproduction.Watervapor
accountsfornearly36%‐66%oftotalharmfulproductsinouratmosphere,buthumanactivitydoesnot
contributetotheproductionofwatervapor,soitisusuallyignoredwhenitcomestoprevention.
TheUnitedStates,asawhole,isdependentupontheautomobilemorethananyothercountry.
About48%ofglobalgreenhousegasemissionsfromautomobilescomefromtheUnitedStatesdespite
theUSmakinguponly5%oftheworld’spopulationandonly30%oftheentirevehiclepopulation
(http://www.edf.org).TheUSgovernmenthassetupapolicytotryandslowtheever‐increasingrateof
carbondioxideemissionsby“strengtheningscience,technologyandinstitutionsandenhancing
6
internationalcooperation”(http://www.epa.gov).Risinggaspricesarealsoamajorconcernwiththe
currentstateoftheeconomy,andthisismagnifiedbecauseoftherelianceontheautomobile.This
leadstobothfinancialandenvironmentalincentivestodevelopacleanerandeconomicalalternativeto
thefossilfuels.
Whileextensiveresearchiscurrentlybeingconductedtodevelopanalternativetofossilfuels,
thereisstillmuchtimebeforetheyareefficientenoughtobecomeacapablesolutiontoour
environmentalproblem,particularlyinthecaseofautomobiles.TheAmericanSolarEnergySociety
recentlyputtogetherareportthatcovers,“energyefficiencyinbuildings,transportation,andindustry,
aswellassixrenewableenergytechnologies:concentratingsolarpower,photovoltaics,windpower,
biomass,biofuels,andgeothermalpower.Theresultsindicatethatthesetechnologiescandisplace
approximately1.2billiontonsofcarbonemissionsannuallybytheyear2030.”(http://www.ases.org).
Untilthesetechnologiescanbeimplementedefficientlywemustlookforothersourcesofenergythat
havethepotentialtomakeadifferenceimmediately.
2.3BiodieselfromWasteVegetableOil:Apossiblesolution?
Biodieselisaverygoodcompromiseuntilnewtechnologiescanbeimplementedbecauseitcan
beconvertedrelativelyeasilyfromwastevegetableoil.Theresultingfuelcanbeusedinanunmodified
dieselengineinapureform,althoughitisnormallymixedwithpetroleumdiesel.Biodieselcanalsobe
usedinboilerstoheatyourhomeorbusinesswithlittleornomodification.
Becausewastevegetableoilisreadilyavailableitisapossibleverycostfriendlysolution,and
thefactthatitismadefromrenewableresourceslowersourdependenceonforeignoilandhelpsour
owneconomy.Biodieselhasalsobeenshowntohelpreducecarbondioxideemissions,whichcanhelp
theglobalwarmingcrisis.“BiodieselreducesnetCO2emissionsby78percentcomparedtopetroleum
diesel.Thisisduetobiodiesel’sclosedcarboncycle.TheCO2releasedintotheatmospherewhen
biodieselisburnedisrecycledbygrowingplants,whicharelaterprocessedintofuel”
(http://www.biodisel.org).Theeffectsofreplacingpetroleumdieselwithbiodieselcouldhaveadrastic
changeontheenvironmentandisasteptowardsourgoalofreducingglobalwarming.
Therearetwodifferenttypesofwastevegetableoil.Thefirsttypeofwastevegetableoilis
browngrease.Browngreaseisthegreasetrapgreasefromstovetopsanddeepfryers.Itisverythick,
dark,andfilledwithimpurities.Thereareabout4to48lbs/personand3,000to24,000lbs/restaurantof
browngreaseproducedinoneyear.Intermsofthebiodieselmarketandproduction,browngreasehas
7
littletonovalue.ThesecondtypeofwastevegetableoilisYellowgrease.Yellowgreaseismadeupof
theoilsandanimalfatsthatareusedandproducedduringcookinganddeep‐frying.(Morea,Sept‐12)Its
productionrangeis3to21lbs/personand2,000to13,000lbs/restaurantinagivenyear.Thisvegetable
oilwastecanbeusedforrenderingandhasbeenestablishedasavaluablecommodityinthebiodiesel
market.(http://www.nrel.gov/vehiclesandfuels)
Biodieselhasmanyvarioussources.Itcanbemadefromvirginoil,producedmainlyfrom
soybeansandrapeseed,wastevegetableoil,usedinthecookingprocess,animalfats,likelardand
tallow,biodieselcanevenbemadefromalgaegrowntoproducevegetableoils.Wastevegetableoil
(WVO)isagoodsourceasitisreadilyavailableatlowcost(Biodiesel,2008).
ThefirstinternalcombustionenginetorunonvegetableoilwasdesignedbyRudolfDieselin
1900.Dieselbelievedthatenginesthatrunonabiomassproductwerethefutureofhisinvention,in
1911;hesaid"Thedieselenginecanbefedwithvegetableoilsandwouldhelpconsiderablyinthe
developmentofagricultureofthecountrieswhichuseit".Theactualpatenttotheprocessinwhich
biodieselismadetoday,calledtransesterification,wasgiventoG.Chavannein1937forhisdesignofthe
transesterificationprocess(Biodiesel,2008).
Asafuelbiodieselisveryversatile,itcanbeappliedtoseveraldifferentareas.Anenginethatis
designedtoburndieselfuelcanbemodifiedtoburnpurebiodiesel,knownasB100.Orthatsamediesel
enginecanburnan80%diesel20%biodieselmixturewithnomodificationatall,knownasB20.Thisis
advantageousasitwillhelptokeepemissionsdownandslightlyincreasemileage.PureBiodiesel,B100,
canalsobeusedasareplacementforhomeheatingoil(Biodiesel,2008).
Biodieselhaspropertiesthatareverydifferentthanotherfuelsonthemarkettoday.Oneofthe
majordifferencesbetweenbiodieselanddieselisthatbiodieselcontainslessenergypergallon,butit
burnsmorecompletely,makingupforsomeofthelossduetosmallerenergydensity.Another
advantagetobiodieselisithasamuchgreaterlubricatingpropertythanotherfuels.Thiscanreduce
wearandprolongthelifeforenginepartsthatrequirethefuelasalubricant,suchasfuelinjectors.
Biodieselalsoburnscleaner;testshaveshownareductioninunburnedhydrocarbons,carbonmonoxide
andsulfuremissions,butaveryslightincreaseinnitrogenoxides.Theflashpointofbiodiesel,the
temperatureatwhichthevaporsabovethefuelbecomeflammable,isabout100oChigherthanthatof
dieselfuel.Thehigherflashpointmakesbiodieselsafertohandleandtransport.Anegativeattributeof
biodieselisitshighcloudpoint.Thecloudpointisthetemperaturewhenaliquidstartstothickenand
8
gel,thismakesitdifficulttouseinaregularinternalcombustionengine(AdvantagesofusingBiodiesel,
2008).Inaddition,biodieselisalsoaneffectivesolvent(StoringBiodieselFuels,2007).
2.4Collection
IntheUnitedStatesthereisapproximately2.9billiongallonsofwastevegetableoilproducedin
oneyear(epa.gov).Mostofthisoilisproducedbyindustrialdeepfryersownedbypotatochipand
snackfoodcompanies.ThiswasteoilisclassifiedasahazardousmaterialbytheDEPandtherefore
forcesbusinessownerstodealwithnotonlythestorage,butthedisposalofthiswaste.Theaverage
costfordisposalofthiswasteisabout150dollars/tonnewhich,whenfactoredintothegenerationof
wasteperyear,equals16billiondollarsforwastedisposal(http://www.mass.dep.gov/).
2.5Storage
Containersarethemostfundamentalmeansofstoringandtransportingmaterials.Containers
comeinvariousshapesandsizesandcanbemanufacturedoutofavarietyofdifferentmaterials.These
containershaveawiderangeofapplicationsincludingthestorageofmaterialsbothaboveandbelow
ground.Duetothelimitedbudget,itwouldbemorecosteffectivetoconsiderabovegroundstorage,
andtoavoidtheaddedcostsofzoningandexcavationforlargeundergroundtanks.Notonlyare
smallertankscheaper,buttheyarealsoreadilytransportableandeasilycleaned.
BiodieselisregisteredwiththeEnvironmentalProtectionAgencyandisclassifiedasan
alternativefuelorfueladditive(Engleman,2002).Biodieselisnotconsideredahazardousmaterialby
theDepartmentofTransportation,anddoesnotrequirespecialpermitstotransport(Engleman,2002).
BiodieselandDieselitselfpossesssimilarproperties,whichmeaneachmustbestoredinsimilar
conditions.Theymustbestoredawayfromsunlight,moisture,oxygen,aswellasanyextremesin
temperature.Subjectiontoanyoftheabovewillleadtodegradationinthefuelpropertiesandcould
renderthemuseless.Onemightthinkthatinordertostorebiodiesel,specialpermitsmustbeacquired.
Infact,themajorityoftheregulationsforstorageofordinarypetroleumdieselfuelpertaintothoseof
biodieselaswell.Recommendedmaterialsforstorageincludesteel,fluorinatedplastics,andhigh
densitypolyethylene.
Methanol,ontheotherhand,isaClass3FlammableMaterial,andconsideredahazardous
materialbytheEnvironmentalProtectionAgencyandOSHA.Methanolisvolatileandwillreadilyreact,
thusitsClass3rating,andcanonlybetransportedinloadssmallerthan755gallonsatatime.When
9
beingstored,thesitemustbeinspectedtoensureprecautionaryfireprotectionandventilationsystems
areinplacetomeetsafetycodes.Theinspectorwillalsosetacapacityastohowmuchmethanolcan
bekeptonsite.Methanolmustbestoredincompletelyenclosedcontainers.Itcannotbeallowedto
oxidizewiththeairorcomeintocontactwithanignitionsource.Stainlesssteel,HighDensity
Polyethylene,andvulcanizednaturalrubberaretherecommendedmaterialsforstorageofmethanolas
theyshowthegreatestresistancetomethanol’scorrosiveproperties.
Metalisanidealmeansofstorageduetoitsabilitytocanceloutsunlight.Metalisalso
non‐permeablesotherewillbenoexchangeofmoistureorairwhenbeingstoredforextendedperiods
oftime.Ifusinganewdrum,adrumwithinteriorliningsmustberesistanttobiodiesel’sandmethanols
solventproperties.Whenusingauseddrum,knowledgeofitspreviousapplicationandcontentsis
importantaswell,asbiodieselmayreactwithanyremnants.Anysubsequentreactionswithinterior
liningsorremnantsfromprevioususagesleadstofueldegradationandmaynegativelyaffectwhichever
systemthefuelisaddedto(Engleman,2008).Metalcontainersarecosteffective,they’recheapto
manufactureandcanbecreatedinlargequantities.Theonlydrawbacktometalcontainersisthatthey
areconsiderablyheavierthanotherstoragedevices.
Fluorinatedandotherhighdensityplasticsarealsoeffectivemeansofstoringbiodiesel.Plastics
thathavebeenfluorinatedreducethepermeabilityofthecontainerandalsoserveasabarrieragainst
biodiesel’ssolventnature.Whenitcomestohighdensityplastics,theyactverymuchlikethe
fluorinatedplasticsinthattheyofferincreasedresistancetoanyreactivitywithbiodiesel.Plasticsare
muchlighterthantheirmetalcounterparts,buthaveanincreasedmanufacturingcost.Thehigherprice
ofthesecontainersisattributedtotheirslowproductionrateandrequiredtooling.Despitethe
drawbackoftheirhigherprice,plasticsarerecommendedovermetalcontainersduetotheirresistance
toreactionwiththenumerousformsofBiofuels(StoringBiodieselFuels,2007).
10
Figure1:SmallStoragetanksandpumpstomoveWVO,Hubbardston,MA
11
2.6Transportation
Transportationisthemeansbywhichyoudeliveryourmaterialstotherequireddestination.
Whenchoosingameansoftransportationwithanintegratedstoragetank,alltheabovementioned
mustbetakenintoconsideration.Materialsaretransportedeverydaybyrail,air,andground.Theonly
meansoftransportationthatthisoperationwillrelyonisthatoftransportationbymeansofground.
Whiletherearefewregulationsonthetransportationofwastevegetableoilandbiodieselthatisnot
thecasewithmethanol.Only755gallonsofmethanolcanbetransportedatatime.Thevehicle
containingmethanolmustdisplayproperflammabletagsandidentificationinaccordancewiththe
DepartmentofTransportation.
Smallpickuptrucksaremoremobileandmorefuelefficient,butdonotoffertheloadcapacity
thatalargeroiltruckcouldoffer.Thus,multipletripswouldhavetobetakentocollectallofyourraw
materialsordisposeofyourwastes.Ontheotherhandlargeoiltankershaveanincreasedpayload
capacity,whichmeansideallyallofyourwastevegetableoilcanbecollectedinonesingletrip.Repairs
forlightdutypickuptrucksarecheaperthanthatforlargertrucks,butunderconstantload,onecan
expectmorefrequentvisitstothelocalmechanic.Largertrucksarebuilttotakepunishmentandwhile
anyrepairwouldcostmorethanusual,onewouldn’texpecttofrequentthemechanictoooften.Each
optionhasitsownadvantagesanddisadvantages.Thebestchoiceforavehiclewouldbeaseptictruck.
Septictrucksdonotsacrificemobilityforcapacity.Theyremainefficientandatthesametimecanhaul
anywherefrom1,000–4,000gallonsofmaterial.Alsothetruckwouldbedieselsoitcanusethe
producedbiodiesel.
2.7ProductionofBiodiesel
2.7.1BatchProcess
ThereareseveralwaystoproducebiodieselfromWVO.Themostwidelyusedwayisthebatch
process.Theincomingoilmustbefilteredtoremoveanysolidswhilethelevelsoffreefattyacidsand
waterarebeingmonitored,toomuchofeithercancauseproblemslaterintheproductionprocess.The
catalyst,lye(NaOH),ismixedwiththealcohol,methanol,thenthealcohol/catalystmixischargedintoa
closedreactionvessel.Thentheoilisadded.Thesystemfromhereonistotallyclosedtothe
atmospheretopreventthelossofalcoholthroughevaporation.Thevesselisthenheatedtobetween
55o–70oCinordertospeedthereactionup.After1‐8hoursofmixing/reactingthereactedliquidis
separated,theheavierglycerinbyproductswillsink,eitherbygravityorbycentrifuge.Afterseparation,
12
theexcessalcoholisdistilledawayorflashevaporatedandrecycled.Theunusedcatalystisrecovered
fromtheglycerinbyproductandisrecycled(Blair,2005).Theglycerinisstoredasitisavaluable
commodity.Thenthebiodieseliswashedwithwarmwatertoremoveanyresidualimpurities.(See
figure1.)
13
Figure2:BatchProcessComponents,Hubbardston,MASite
Clockwisefromtopright:MethanolRecovoryTank,FilterforWVO,HeatSourceforProcess,MixingandSettlingTanks.
14
Figure3:Schematicofabatchprocess.Courtesyofbiofuelsservices.com
15
2.7.2Ultrasonication
Ultrasonicationisanewerwaytoproducebiodiesel.Themethanolandcatalystarepre‐mixed
likeinthebatchprocess;thismixtureiscombinedwiththeoil.Themixtureisusuallyheatedto50o–
60oC,whilebeinghitwithultrasonicsoundwaves.Thesoundwavescauseaphenomenoncalled
cavitation,wherebubblesarerandomlycreatedandimplodedwithincrediblefrequency.These
cavitationsprovidebothenoughmixingandtheneededactivationenergyforthetransesterificationto
takeplaceinamuchshortertimethanthebatchprocess.Thenthereactedmixtureisphaseseparated,
washedandstoredasbefore(Hielscher,).Thisprocesshasseveraladvantages:itismuchmoreenergy
efficientthanthebatchprocess,ittakesmuchlesstimetocreateanequivalentamountofbiodiesel,
anditisrunasacontinuousprocess(Gogate,Kelkar,Pandit,2005).(Seefigure2.)
16
Figure2:Schematicofanultrasonicprocess.HeilscherTechnologies.
17
2.7.3SupercriticalMeOH
Oneofthenewestwaystoproducebiodieselusesmethanolinasupercriticalstate.Asubstance
inasupercriticalstateisneitheraliquidnoragas,butstillretainspropertiesofboth.Inordertoreacha
supercriticalstate,thesubstancemustbeatasuperhightemperatureandpressure.Formethanol,it
mustbeover650oFand5000psi.Oneofthemainadvantagesisthatthisprocessisincrediblyfast.Itis
abletoreactsimilaramountsofoilasthebatchprocessinaslittleas6minutes.Anotheradvantageto
usingsupercriticalmethanolisthatthereactioniscompletelyspontaneous,meaningnocatalystis
needed.Thethirdadvantagemaybethegreatest;thisprocessismuchmoretolerableofexcesswater
andfreefattyacidsinthefeedstock.Thatmeansthatitcanacceptandsuccessfullyreactamuchwider
rangeoffeedstocksasthequalitydoesn’tneedtobeashigh(Hegel,Mabe,Pereda,Brignole,2007).
Therearenegativeattributestothisprocess.Startupcostswouldbehugeastheequipmentneedsto
beabletohandlehugetemperaturesandpressures.
2.8Safety
2.8.1NFPASafetyratingsystem
Safetyisalargeconcernwhendealingwithanytypeofprocess,especiallychemical.The
NationalFirePreventionAssociation(NFPA)hasafourcolorcategoryratingsystemforallmaterialsto
beusedintheproductionprocess.(Seefigure3.)Thefourcategoriesarehealth,fire,reactivityand
specifichazards.Eachcategoryhasitsownnumberratingfrom0to4with4beingthegreatestrisk.
Health(blue)definestheriskifexposedtothesubstanceforanyperiodoftime.Flammability(red)deals
withtheflashpointofamaterialorunderwhatcircumstancesthematerialwillignite.Reactivity
(yellow)isthelikelihoodandconditionsthatamaterialwilldetonateorexplode.Finally,theSpecial
Hazard(white)categoryindicatesspecialcharacteristicsthatamaterialmayhave,e.g.oxidizer,acid,
biologicalhazard,etc.
18
Figure3:ExampleofaNFPAratingsystem
19
2.8.2RatingoftheChemicalsUsed
Theproductionprocessesbywhichbiodieselisproducedrequirescertainchemicalsand
compoundsthatmustbeidentifiedandacknowledged.Thesechemicalsincludemethanol,waste
vegetableoil,lye,phenolphthalein,isopropanol,glycerol,andthefinalproductofbiodiesel.Each
substancehasitsownNFPAratinganditsownhandlingrequirements.
Methanolisahighlyflammablesubstancenecessaryforthetransesterificationprocess.
AccordingtotheNFPA“firediamond”,methanoliscategorizedasHealth:2,Flammability:3and
Reactivity:0.Itistoxicifinhaled,digestedorabsorbedthroughtheskin,aswellasbeinghighly
flammable.Methanolshouldbestoredinacooldryplaceawayfromheatandsparksintightlyclosed
containersnotmadefromaluminumorlead.Whenhandlingmethanolanoperatorshouldwear
chemicalprotectiveclothing(glovesandgoggles)andifinpoorlyventilatedarea,aself‐contained
breathingapparatus(SCBA).
Lye(NaOH)isacorrosivewhitesolidthatisthecatalystinthereaction.ItsNFPAratingisHealth:
3,Flammability:0,andReactivity:1.Lyecancausesevereburnstotheeyes,skin,andrespiratorytract
aswellasbeingharmfulorfatalifinhaledorswallowed.Lyeisnotflammablebutreactswithmost
metalsandwater.Lyeistobestoredinacool,wellventilatedareaintightlyclosednon‐metal
containers.Protectiveclothing,gloves,andgogglesarerequiredwhenhandlinglye.
Therawwastevegetableoilisaclearlightyellowoilyliquidwithafattyodor.IthasaHealth0,
Flammability:1,andReactivity:0ontheNFPAratingscale.Wastevegetableoilisnon‐toxicandhasa
verylowflammability.Itshouldbestoredinacool,dry,wellventilatedplace.Onlyglovesandgoggles
aresuggestedwhenhandlingthismaterial.
Phenolphthaleinisaclear,colorlessliquidusedasanacid/baseindicator.IthasaNFPAratingof
Health:2,Flammability:1,andReactivity:0.Phenolphthaleinmaycausecancerduetooverexposure
andshouldbekeptawayfromheat,sparks,flame,halogensandstrongoxidizers.Itshouldbestoredin
adequatelyventilatedareasandhandledwhilewearingsafetygogglesandgloves.
Isoproanolisacolorlessliquidwithanalcoholodorandisusedasanorganicsolventinthe
titrationprocess.IsopropanolhasaNFPAratingofHealth:2,Flammability:3,andReactivity:0.Itisa
highlyflammableliquidandisasevereeyeirritant.Glovesandgogglesshouldbewornwhenhandling
isopropanol.
20
Glycerol,theby‐productofthebiodieselprocess,isaclearandodorlessoilyliquid.Thesafety
ratingofglycerolisHealth:2,Flammability:1,andReactivity:0.Glycerolhasalowflammabilityand
toxicity,itisamildirritanttotheskinandeyes,andifingestedcancausedamagetothekidneys.It
shouldbestoredinacool,wellventilatedplaceandprotectedagainstphysicaldamage.Glovesand
gogglesshouldbewornwhenhandlingGlycerol.
Thefinalproduct,Biodiesel,isalightgreenoryellowliquidwithamildfuelodor.Biodieselisa
flammablematerialthatshouldbekeptawayfromheat,flames,staticelectricity,andstrongoxidizers.
Goggles,glovesand/orfaceshieldshouldbewornwhenhandlingbiodiesel.
Understandingwhatisnecessaryforhandlingthesematerialsisimportantwhensettingupa
successfulprocess.Whenhandlingthesematerialseveryworkerneedstohaveaccesstoprotective
gogglesandgloves.Theareaswherethechemicalsarestoredandtheareainwhichtheprocessoccurs
needtobeproperlyventilatedtopreventfireandrespiratoryhazards.Eyewashstations,emergency
showers,andfireextinguishersneedtobeaccessibletoemployeesatalltimes.
21
3.0Methodology
ThegoalofthisprojectwastodesignandbuildafunctioningbiodieselplantforEPOCA.Inorderto
attainthisgoal,weneededtofirstresearchavailabletechnologiesfortransformingwastevegetableoil
intobeneficialbiodiesel.Giventhisknowledge,wethenhadtodetermineavitalsetofcriteriathat
mustbekeptinmindduringtheproject.Giventhesecriteriaandtheavailabletechnologies,wethen
hadtodeterminewhichmethodofbiodieselproductionwouldbenefitEPOCAthebest.Ournexttask
wouldbetocompileallresearchandinformationandpresentthemtoEPOCAsoastomakeour
proposal.Thefollowingpresentsourmethodologyforaccomplishingtheseobjectives.
3.1DetermineCriteria
Todeterminehowtoapproachtheproblemofsettingupamanufacturingprocessforbiodiesel,
weeklymeetingswereheldwithEPOCA.RepresentativesfromEPOCA,specificallythoseinvolvedwith
theprojectgroupEmpower,metonceaweekwithboththemarketingandproductionteamsfromWPI.
TheEmpowergroupconsistedofJuanOtero(Manufacturinghead),SarahAssefa(Treasurer),aswellas
otherassistantsandvolunteers,mostnotablyLonnie.Meetingsraninasemi‐formalfashion,EPOCA
wouldgivestatusreportsonwhattheyhavebeenworkingonthepastweek,budget,andgoalstheyhad
forthefuture;thenthemarketingandproductionteamsgavetheirreports.Afterreports,bothWPI
teamswouldaskEPOCApre‐preparedquestionsthatcameupduringtheirweek’swork,focusingon
criteria,andwhattheywantedeachteamtoaccomplishforthenextmeeting.
3.2DetermineanOptimalSystem
Inordertodeterminejusthowthebatchprocessworks,thesystemdynamics,vital
components,aswellaslearningmoreaboutbiodiesel,weneededtocontactvariouspeopleand
organizations.Byviewingotherpeople’ssystemsfirsthand,wecanusethemasatemplateandaddor
subtractwhereverweseefit.OneofthefirstpeoplewewereputincontactwithwasSteve,ofSteve’s
AutobodylocatedonChandlerStreetinWorcester.Therewelearnedthecostofconvertingdiesel
vehiclestorunonbiodiesel.StevethenshowedushisFordtruckwhichheconverted,starteditup,and
wasrunningitonfilteredwastevegetableoil.AnotherbeneficialcontactwasBruceFiene.Heshowed
ushowtorefineWVO.HetoldusthatfilteredWVOcanbeblendedwithregulargasolineandberunin
adieselengine.Herunsa95‐5percentmixtureofWVOtogasinthesummerandan85‐15percent
mixtureinthewintertopreventtheoilfromthickening.Unfortunatelywewereunabletomakecontact
22
withwhatwouldhaveprovedtobetwoveryimportantsources:“Ready,Willing,andAble,”and
“WachusettBiomass.”Ready,Willing,andAbleisanorganizationverymuchlikeEPOCA.Theyemploy
ex‐prisonersandthehomelesstoruntheirownbiodieselproductionprocess.Theirexperiencewould
haveprovedbeneficialandwouldhavehelpedEPOCAwithanyquestionsorsolvecommonproblems.
WachusettBiomassisalocalcompanythatcollectsoilandproducesbiodiesel.Itwouldhavebeen
helpfultohavebeenabletoseeafullyfunctioningbiodieselplantanddocumenttheirsystemasa
template.AbigbreakcamewhenEPOCAlearnedofabuildingcomplexinHubbardston,Massachusetts
thathadabiodieselsystemonsite.Wemadearrangementsandoneafternoon,membersofourgroup
andEPOCAdroveouttoHubbardstonandviewedthesystem.Wetookpicturesandnotedthesetup
andusedthisasthebasisforthesystemwhichwebuiltforEPOCA.
EPOCA’smainconcerniswhatsystemthey’llbeabletoaffordwiththeirallottedbudget.An
outlineofthevariousbiodieselproductionsystemsavailablewascreated.Theoutlinecategorizedeach
individualprocessinto3differentpriceranges.Thepricerangesweredeterminedbyusingtheaverage
costofthesystemandsustainability,assuppliedbyInternetbiodieselproductionsystem
manufacturers.Internetresearchwasdonetoreverseengineereachprocessinordertomakeadetailed
partslistofeachsystem.Individualpricesofthemaincomponentsofeachsystemwerefoundthrough
InternetbiodieselproductionsystemmanufacturerstopresenttoEPOCAthecostbenefitsofpurchasing
eachcomponentseparatelyandbuildingacustom‐madebiodieselsystem.
3.3MakePresentationtoEPOCA
Afterthecostandbenefitdatawascollected,itwasorganizedandpresentedtoEPOCA.The
datawaspresentedtoEPOCAatoneoftheweeklymeetingswithSarah,JuanandothersfromEPOCAas
wellastheproductionandmarketingteams.Aspreadsheetoutliningtheinformationtoassesand
analyzeourdatawaspresentedtotheEPOCAteam.
Eachofthedifferentprocesseswasdescribedindetail,fromtheactualsciencebehindittowhat
eachpartintheprocessdid.Theprosandconsofthedifferentmethodswereweighedcarefullyagainst
eachother;criterialikeenergyefficiency,personnelneedsandtraining,productquality,finalyield,etc.
Muchtimewasspentonthisdiscussionasitwouldbeamajorfactorwhenselectingthefinalmethodof
production.
23
4.0Analysis
4.1Explanationofratingsystemused
Thenexttask,aswellasthemostimportant,wastodeterminetheoptimalsystemforEPOCA.
First,allpossiblecriteriahadtobeconsidered.Thesecriteriaareasfollows:efficiency,upgradability,
personnelrequirements,safety,andcosteffectiveness.Inordertoanalyzethese,a“qualitycube”was
createdtogiveavaluetoeachcriterion,foreachofthethreemethodsofbiodieselproduction.Each
valuewasgiveneitheranumericalvalueonascalefrom1to5.
OneofEPOCA’smainconcernsforitspilotprojectisefficiency.EPOCAneedsasystemthatis
timeefficientandwillproducebiodieselatmaximumcapacity.Tomaximizeproductivity,EPOCAwould
needasystemtominimizethetimeittakestoreact,settle,andwashtheirbiodiesel.Firstletus
considerproductioncapacity.Capacitywasdeterminedbythetotaltimeittakestoproduceasingle
batchofbiodiesel.Avalueof1meansthatittakesgreaterthan8hourstoyieldaproduct,andavalue
of5meansthatittakeslessthanorequalto1hourforayield.AlsocontainedunderefficiencyisYield.
Yieldisthepercentageofmaterialthatcanberecoveredfromtheprocess.Morespecifically,howmuch
productiscreatedandhowmuchoftherawmaterials,suchasmethanol,canberecycled.Yieldwas
rankedfrom80%efficiencyto100%efficiencywithincrementsof5%.Todetermineafinalvaluefor
efficiency,theaverageofthesetwovalueswastaken.
UpgradabilityisimportantsoEPOCA’ssystemcanexpandalongwiththeircustomerbase.Parts
needtobechoseninsuchawaythattheycaneasilybeswappedoutoraddedoninplaceofpartswith
greaterqualitythatcanincreasecapacityandefficiency.Upgradabilitywasgivenaqualitativerank.
Thisrankrangedfrom1,notbeingabletoacceptupgradesatall,to5,whereallpartshavethepotential
tobeupgraded.
Understandingthattrainingisneithercostnortimeeffective,EPOCAwantstheirpilotplantto
beaseasytooperateaspossible.Workload/Stressloadisconsideredwhendesigningaprocessing
plant.Ideally,thesystemstepswouldbelinear;meaningthatthenextstepislocatednexttothe
previous.Workloadwasalsogivenaqualitativesetofvalues.Avalueof5indicatesthatnohuman
interactionisneededfortheprocess,meaningthatthesystemiscompletelyautonomous,andavalue
of1indicatesthatthehumanworkloadisextremelyintenseanddemanding,meaningworkersneedto
bepresentineverystageoftheprocess.Alsounderpersonnelrequirementsiscomplexityofparts.The
systemcannotbeoverlycomplex.Arraysofbuttons,lights,andswitchesarenotwhatEPOCAislooking
24
for.Thesamequalitativerankingsystemthatisusedforworkloadisalsousedforcomplexityofparts.
Avalueof5meansthatpartsarenotcomplexandareeasytoreplaceandavalueof1meansthatparts
areoverlycomplexandcompleteknowledgeofthesystemiscritical.Toattainafinalvaluefor
PersonnelRequirements,theaverageofthetwocategorieswastaken.
Thisprojectisattemptingtohelpexpandgreenjobs.Ifthesystemwerenotsafeforboththe
environmentanditsworkers,thenitdefeatsthepurpose.Theidealsystemwouldbeonethatproduces
aslittlewasteaspossible,wastethatwouldhurttheenvironment,aswellasbeasafeenvironmentfor
itsworkers,freeoftoxicfumesandcontactwithharshchemicals.Safetywasdeterminedbythe
protectiveequipmentthatmustbeworn.Anumber5denotesthebasicsafetyequipmentlikegoggles
andgloves.Thenumber1denotessafetyequipmentsuchasHAZMATsuitsandself‐contained
breathingapparatus’.
Thefinalcriterion,aswellasthelimitingone,wasthatofcost.Costencompassesthreesub‐
categories:StartupCost,Production/OperatingCost,andMaintenanceCost.Startupcostdenotesthe
moneyexpectedtopayforallcomponentsthatmakeupthesystemaswellasanylegalfees,permits,or
licensingneededtobegintheoperation.Production/Operatingcostistheexpectedcostofraw
materials,energyconsumption,andinsuranceandlegalfeesthatarerequiredtokeepthesystem
runningfromyeartoyear.Maintenancecostistheexpectedcostofallreplacementpartsthatmaybe
neededtomaintainandsustainoperationsthroughouttheyear.Anumericalrankingsystemwasused
forthesethreesystems.Arankof5denotedthattheexpectedcostwouldbelessthan$5,000anda
rankof1meantthattheexpectedcostwouldbegreaterthan$25,000.Todeterminethefinalvalue
placedoncost,theaverageofthesethreecategorieswastaken.
4.2BatchProcess
Thebatchprocessisthemostwidelyknownbiodieselconversionprocessbecausea
rudimentarysystemisrelativelyinexpensive,andeasytooperate.Thismakesthebatchprocessideal
forthepeoplewhoonlywishtoproduceenoughfuelfortheirownuse.However,theversatilityofthe
“batchprocess”easilyallowsforaproductionincrease,makingittheperfectbiodieselconversion
processforsmallcompanieslikeEMPOWER.
4.2.1Cost–Avg.Score:5
25
Themainbenefitofthebatchsystemistheextremelylowstart‐upcostcomparedtoother,
morecomplexsystems.Apilotplantconsistingof3tanks,2pumpsandtherespectivehosesandfittings
cancostwellunder$2000.Largertanksandmorepowerfulpumpscanbeusedtoincreasethe
productioncapacitywhilestillkeepingthepricewellunder$5000.
Productioncostsarealsomoreinexpensivethanotherbiodieselsystems.Pricesforlegal
permitsandinsurancearethesameorlowerthanotherprocessesthatrequirehighertemperatures
and/orpressures.Rawmaterialpricesaregenerallyfixed,butcompaniesusuallygiveadiscountwhen
buyinginlargequantities.ThisisbeneficialtoEMPOWERbecausetheproductioncostsassociatedwith
rawmaterialswillactuallydecreaseasmorebiodieselisbeingproduced.
Maintenanceforthebatchsystemisminimal.Itrequiresreplacingpartsthatmalfunction,which
areinexpensivetopurchaseandreplace.
4.2.2Upgradability–Avg.Score:5
Anothermainbenefitofthebatchprocessisthehighupgradabilityofthesystem.Upgradingthe
systemtoincreasetheproductioncapacityisassimpleasincreasingthetanksizeand/oraddingmore
tanks.However,asmoreandmoretanksareadded,spacedoesbecomeaconcern.
4.2.3Efficiency–Avg.Score:3
Adownsideofthebatchprocessisthelowefficiencycomparedtoother,moreexpensive
systems.Onecanexpectefficiencybetween85%and90%forthetypicalbatchprocess.Amethanol
recoverysystemcanalsobeimplementedtorecoveralmost85%ofthemethanolusedintheprocess.
4.2.4PersonnelRequirements–Avg.Score:2
Becauseofthevolatilityofthechemicalsusedandthetemperaturerequiredfor
transesterification,personnelmustbepresentatalltimes.Anemployeeisexpectedtousethepumps
totransfertheWVO/Biodieselbetweentanks,addspecificamountofchemicals,andcontrolthe
temperatureoftheheatingelement.Trainingforpersonnelisrelativelystraightforward,asmostofthe
workbeingdoneissimple.Personalresponsibilityismoreessentialtothejobthananyuniqueskillset.
26
Table2:BatchProcessRatingChart
!"#$%&'()#*+&
&& & &
!"#$%
,-./&
0"12*3&
4&
&&&''()(*+),%
,-./&
0"12*3&
5&
&&&&
6&7894:;;;&
9<89;:;;;&
5<864:;;;&
=<86;:;;;&
4>84;;;&
&&&&
6>?;@&
9<?4@&
5<A;@&
=<A4@&
4<6;;@&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
BC*1D3&
&&&&
'#"E#2F&
GH)#3&
I*JH#*)&#%*&+
HJ*(&*KF*$#*D&#H&F"(&LHE&$H+FHJ*J#)&"J&"11&H#%*E&
+"#*EC"1)&J**D*D&#H&)#"E#&FEH$*))&
&&
M#&C)&#%*&F*E$*J#".*&HL&+"#*EC"1)&N*&$"J&E*$H-*E&
LEH+&#%*&FEH$*))&
&&&&
&&&&
&&&&
0"12*3&
4&
&&&&
&&&&
0"12*&
9&
&&&&
&&&&
&&&&
&&&&
&&
6&7&
?%H2E)&
97O%H2E)&
57=%H2E)&
=79%H2E)&
4&<&6&%H2E&
&&&&
&&&&
&&
&&&&
&&PEHD2$#CHJQ&RF*E"#CJ.&
GH)#3&
&&
SKF*$#*D&$H)#)&HL&E"N&+
"#*EC"1)&"JD&*J*E.(&
2)*&
TC+
*Q&
G"F"$C#(3&
M#&C)&#%*&#C+
*&C#&#"U*)&#H&FEHD2$*&"&)CJ.1*&V"#$%&HL&
VCHDC*)*1&
&&&&
&&&&
&&&&
0"12*3&
4&
&&&&
&&&&
0"12*3&
=&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
&&-*./0+*1%2*34(.*5*+6/%
,-./&0"12*&
9&
W"CJ#"CJ"J$*&GH)#3&
&&
SKF*$#*D&$H)#&HL&E*F1"$*+*J#&F"E#)&
&&&&
6X-*E(&
9X)#EHJ.&
5X)H+*N%"#&
=X&1C##1*&
4XJHJ*&
&&&&
&&&&
0"12*3&
4&
&&
&&&&
&&&&
&&&&
&&
#7'*6,%
0"12*3&
4&
&&
YHEU1H"DQ&'#E*))&
ZH"D3&
T%*&NHEU&"JD&)#E*))&1*-*1)&"&NHEU*E&NC11&*J$H2J#*E&D2ECJ.&"&)CJ.1*&D"(&HL&
NHEU&
6X[,\W,T:&
VE*"#%CJ.&
"CD&
9X'2C#):&
L"$*)%C*1D&
*#$&
5X'2C#)&
*#$&
=X,FEHJ):&
.1H-*):&
.H..1*)&
4X]1H-*):&
.H..1*)&
&&&&
&&&&
&&&&
&&0"12*3&
9&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
8-92:;&:<=>=$?%
&&0"12*3&4&
&&&&
&&
6X^H#&"#&"11&
9XWCJ/&
5XP"E#C"11(&
=XW"_HEC#(&
4XTH#"11(&
&&&&
GH+F1*KC#(&HL&P"E#)3&
[HN&*")(&C)&C#&#H&E*F1"$*&F"E#)`&&G"J&E*F"CE)&V*&DHJ*&CJa%H2)*`&
&&&&
&&&&
&&&&
&&&&
&&&&
&&&&
0"12*3&
9&
27
4.3ContinuousBatchProcess
Thesecondprocessthatweanalyzedwasthecontinuousbatchprocess(CBP).Thisprocessis
verysimilartothebatchprocess,buthasafewmajordifferences.Thesedifferencesincludeamethanol
recoverysystemandmoretanksformixingandsettling.Whenthissystemwasputintothequalityqube
itscoredanaveragevalueof3.5.
4.3.1Cost–Avg.Score:3.5
Thefirstthinganalyzedinthisprocesswasthecost.TheCBPscoreda3forstart‐upcost.
Thoughnosinglepartoftheprocessisoverlyexpensive,purchasingthequantityoftankstoset‐upa
properprocesscangetcostly.Thenextthingstoconsiderinthecostcategoryareproduction/operating
costsaswellasmaintenancecost,onwhichtheCBPscoreda4.Althoughthestart‐upcostsarehigherin
thisprocess,thecostofoperationisratherlow.Themethanolrecoverysystemfeaturedinthisprocess
willsaveonthepurchaseofrawmethanolandthereforelowerproduction.Maintenancecostsarelow
duetothesimplicityofthesystemandwithmostofthepartsavailableatanylocalhardwarestore.
ThenextCriteriontobeconsideredwassafety.Usingthequalitycube,thesafetyofthissystem
wasgivenavalueof3.Avalueof3indicatesthatwhilethisprocessissafe,properventilationandsome
protectiveequipmentisrequired.Theprocessusescorrosivematerials;thereforeprotectiveglovesand
possiblyafaceshieldarerequiredatsomepointduringtheprocess.Also,withthenumberoftanks
beingusedintheCBP,properventilationisnecessaryforoperationandthesafetyoftheoperator.
4.3.2Upgradability–Avg.Score:5
Third,theupgradabilityoftheprocesswasevaluated.TheCBPhadaveryhighupgradability,
scoringa5onthescale.TheCBPscoreda5onthisscalebecauseeveryaspectofthesystemcanbe
upgraded,sinceitisbasicallyanupgradedbatchprocess.Moresettlingandmixingtankscanbeadded
toincreasetheoutputofthesystem.Partssuchasthemixingcomponents,pipes,pumps,andfilterscan
allbeupgradedatanytimewhenconvenienttoincreaseproductivity.
4.3.3Efficiency–Avg.Score:3
Efficiencywasthefourthcriterialookedatwhenanalyzingtheprocess.Theefficiencywassplit
intotwosub‐categories;yieldandtime/capacity.Foryield,theCBPscoreda2whichmeansthatthe
28
processoverallhasapercentyieldofaround85%.FortheCBP,evaluationoftime/capacityiscomplex
whichiswhyitwasgivena3.Thiscriterionisdependentonthenumberoftanksintheprocess.The
timeforasinglebatchwillbeequaltothatoftheregularbatchprocess;howeverwhenmultiple
batchesareinprocessmuchmorecanbeproducedthantheoriginalprocessinaday.
4.3.4PersonnelRequirements–Avg.Score:2.5
Thefinalcriterionwasthepersonnelrequirementsoftheprocess.Thiscategoryincludesthe
workloadstressontheoperatorandthecomplexityofthesystemanditsparts.Inthesub‐categoryof
workloadstresstheCBPhadavalueof2.TheCBPhasavalueof2becauseanoperatorwillbeincharge
ofrunandcheckingonmultipletanksatatime.Tokeepupwithprocess,theoperatorwillneedtobe
abletoeffectivelytransfermultiplebatchesatatimeandorchestratetheminthepropersequence.A
complexityvalueof3wasgivenduetothesimplicityofthesystemanditsparts.Thisprocessdoesnot
requireanypriorknowledgeofthesystemtooperateandmostlyinvolvestheopeningandclosingof
valves.Onlysimpleprocesstrainingwouldberequiredtoeducateonetoeffectivelyruntheprocess.
29
Table2:ContinuousBatchProcessRatingChart
!"#$%#&"&'()*$+,(
(
!"#$%
-./0(
1*2&34(
506(
((&''()(*+),%
-./0(
1*2&34(
5(
((((
7(89:6;<<<(
:=9:<;<<<(
5=976;<<<(
>=97<;<<<(
6?96<<<(
((((
7?@<A(
:=@6A(
5=B<A(
>=B6A(
6=7<<A(
((((
((((
((((
((((
((((
((((
((((
((((
C%32D4(
((((
E$*F$&G(
!"'$4(
H3#"$3'($,3(I
"#3J(3KG3+$3D($"(G*J(L"F(+"IG"#3#$'(*#(*22("$,3F(
I*$3F%*2'(#33D3D($"('$*F$(GF"+3''(
((
M$(%'($,3(G3F+3#$*/3("L(I*$3F%*2'(N3(+*#(F3+".3F(
LF"I($,3(GF"+3''(
((((
((((
((((
1*2&34(
5(
((((
((((
1*2&3(
:(
((((
((((
((((
((((
((
7(8(
@,"&F'(
:8O,"&F'(
58>,"&F'(
>8:,"&F'(
6(=(7(,"&F(
((((
((((
((
((((
((PF"D&+$%"#Q(RG3F*$%#/(
!"'$4(
((
SKG3+$3D(+"'$'("L(F*N(I
*$3F%*2'(*#D(
3#3F/J(&'3(
T%I
3Q(
!*G*+%$J4(
M$(%'($,3($%I
3(%$($*U3'($"(GF"D&+3(*('%#/23(V*$+,("L(
V%"D%3'32(
((((
((((
((((
1*2&34(
>(
((((
((((
1*2&34(
>(
((((
((((
((((
((((
((((
((((
((((
((((
((-*./0+*1%2*34(.*5*+6/%
-./0(
1*2&3(
:06(
W*%#$*%#*#+3(!"'$4(
((
SKG3+$3D(+"'$("L(F3G2*+3I3#$(G*F$'(
((((
7X.3FJ(
:X'$F"#/(
5X'"I3N,*$(
>X(2%$$23(
6X#"#3(
((((
((((
1*2&34(
5(
((
((((
((((
((((
((
#7'*6,%
1*2&34(
5(
((
Y"FU2"*DQ(E$F3''(
Z"*D4(
T,3(N"FU(*#D('$F3''(23.32'(*(N"FU3F(N%22(3#+"&#$3F(D&F%#/(*('%#/23(
D*J("L(N"FU(
7X[-\W-T;(
VF3*$,%#/(
*%D(
:XE&%$';(
L*+3',%32D(
3$+(
5XE&%$'(
3$+(
>X-GF"#';(
/2".3';(
/"//23'(
6X]2".3';(
/"//23'(
((((
((((
((((
((1*2&34(
:(
((((
((((
((((
((((
((((
((((
((((
8-92:;&:<=>=$?%
((1*2&34(6(
((((
((
7X^"$(*$(*22(
:XW%#0(
5XP*F$%*22J(
>XW*_"F%$J(
6XT"$*22J(
((((
!"IG23K%$J("L(P*F$'4(
["N(3*'J(%'(%$($"(F3G2*+3(G*F$'`((!*#(F3G*%F'(V3(D"#3(%#a,"&'3`(
((((
((((
((((
((((
((((
((((
1*2&34(
5(
(
30
4.4Ultrasonication
4.4.1Cost–Avg.score:2
Ultrasonicationisaveryeffectiveprocessfortheproductionofbiodieselusingsoundwavesto
drivethereaction.Startupcostsforanultrasonicsetupcanbeverylarge,asmuchasonehundred
thousanddollars.Thatiswhythisprocessreceiveda1forthescoreofstartupcosts.Acombinationof
lotsofexpensivemechanicalandelectricalequipmentdrivesthecostup.
Theoperatingcosttorunanultrasonicprocessismuchsmallerthanonewouldthinkatfirst.
Whilebeingaverycomplicatedprocesswithlotsofcomplexmachinery,itisveryenergyefficientand
theprocessrequiresverylittlefromtheoutside.Theultrasonicprocessreceivesabetterscoreforthe
operatingcosts,4
Maintenanceonanultrasonicoperationcouldbeverygreat.Thereisalotofcomplex
equipmentrunningathightemperaturesandpressuresthatwouldrequireacertifiedtechnicianto
repair.Otherprocessesthathavemoresimplecomponentsrequireonlybasicskillstorepair.
Ultrasonicationreceivesa2forthecostofmaintenance.
4.4.2Upgradability–Avg.Score:1
Theultrasonicprocessisdifficulttoupgrade.Oncetheprocessissetinplaceitwouldneedtobe
disassembledandputbacktogetherwithnewpartandcomponents.Someofthemoreimportantparts
suchastheultrasonictransducercouldbeusedforagreatercapacity,ifitwascapable.
4.4.3Efficiency–Avg.Score:5
Ultrasonication,whilebeingexpensive,isveryefficient.Thepercentyieldsfromtheprocessare
oftengreaterthan98%.Ultrasonicationisalsocapableofacceptingagreatervarietyofrawmaterials,
meaningtheWVOdoesnothavetobefilteredasextensively.Thismakestheprocessmoreefficient
fromstarttofinish.Thisprocessgetsa5foryield.
Theultrasonicprocessismuchfasterandmoreenergyefficientthanmostotherprocesses
availabletoday.Duetotheuniquemethodofdrivingthetransesterificationprocess,ultrasonication
useshalftheenergyoftheaveragebatchprocess.Itisalsomuchfaster,theprocesscanproducethe
31
sameamountofbiodieselproductinlessthanaquarterofthetime.Itgetsa5forthetime/capacity
rating.
4.4.4Personnelrequirements–Avg.score:2
TheStresslevelfortheemployeesinanultrasonicplantwouldbemuchlowerthaninother
productionplants.Thesystemismostlyautomatedanddoesnotrequireamajorinputfromthe
operators.Theoverallstressleveloftheultrasonicprocesswouldbea2.
Thecomplexityoftheultrasonicprocesswouldbemuchlargerthanmostotherprocesses.The
employeewouldberequiredtoknowtheprocesswell,boththepartsandthecomputersinvolvedwith
theprocess.Unfortunatelytheultrasonicequipmentwouldprobablynotbeabletorepairinhouse,
outsidetechnicianswouldberequired.
32
Table3:UltrasonicationRatingChart
!"#$%&'()*%#)'(+
!"#$%
,-./+
0%"123+
4/5+
++&''()(*+),%
,-./+
0%"123+
5+
++++
6+7895:;;;+
9<89;:;;;+
4<865:;;;+
=<86;:;;;+
5>85;;;+
++++
6>?;@+
9<?5@+
4<A;@+
=<A5@+
5<6;;@+
++++
++++
++++
++++
++++
++++
++++
++++
B)2"C3+
++++
D#%$#1E+
F'+
G2('#2&+#H2+I
'(2J+2KE2*#2C+#'+E%J+L'$+*'IE'(2(#&+%(+%""+'#H2$+
I%#2$)%"&+(22C2C+#'+&#%$#+E$'*2&&+
++
M#+)&+#H2+E2$*2(#%.2+'L+I%#2$)%"&+N2+*%(+$2*'-2$+
L$'I+#H2+E$'*2&&+
++++
++++
++++
0%"123+
6+
++++
++++
0%"12+
5+
++++
++++
++++
++++
++
6+7+
?H'1$&+
97OH'1$&+
47=H'1$&+
=79H'1$&+
5+<+6+H'1$+
++++
++++
++
++++
++P$'C1*#)'(Q+RE2$%#)(.+
F'+
++
SKE2*#2C+*'&#&+'L+$%N+I
%#2$)%"&+%(C+
2(2$.J+1&2+
T)I
2Q+
F%E%*)#J3+
M#+)&+#H2+#)I
2+)#+#%U2&+#'+E$'C1*2+%+&)(."2+V%#*H+'L+
V)'C)2&2"+
++++
++++
++++
0%"123+
=+
++++
++++
0%"123+
5+
++++
++++
++++
++++
++++
++++
++++
++++
++-*./0+*1%2*34(.*5*+6/%
,-./+
0%"12+
9+
W%)(#%)(%(*2+F'+
++
SKE2*#2C+*'&#+'L+$2E"%*2I2(#+E%$#&+
++++
6X-2$J+
9X&#$'(.+
4X&'I2NH%#+
=X+")##"2+
5X('(2+
++++
++++
0%"123+
9+
++
++++
++++
++++
++
#7'*6,%
0%"123+
5+
++
Y'$U"'%CQ+D#$2&&+
Z'%C3+
TH2+N'$U+%(C+&#$2&&+"2-2"&+%+N'$U2$+N)""+2(*'1(#2$+C1$)(.+%+&)(."2+
C%J+'L+N'$U+
6X[,\W,T:+
V$2%#H)(.+
%)C+
9XD1)#&:+
L%*2&H)2"C+
2#*+
4XD1)#&+
2#*+
=X,E$'(&:+
."'-2&:+
.'.."2&+
5X]"'-2&:+
.'.."2&+
++++
++++
++++
++0%"123+
9+
++++
++++
++++
++++
++++
++++
++++
8-92:;&:<=>=$?%
++0%"123+6+
++++
++
6X^'#+%#+%""+
9XW)(/+
4XP%$#)%""J+
=XW%_'$)#J+
5XT'#%""J+
++++
F'IE"2K)#J+'L+P%$#&3+
['N+2%&J+)&+)#+#'+$2E"%*2+E%$#&`++F%(+$2E%)$&+V2+C'(2+)(aH'1&2`+
++++
++++
++++
++++
++++
++++
0%"123+
9+
+
33
5.0ConclusionsandRecommendations
ThegoalofthisprojectwastoselectanappropriatebiodieselproductionprocessforEPOCA.
EPOCAisacooperativebusinesswhichemploysprisonersandex‐prisonerswhowouldnormallynotbe
abletofindwork.EPOCA,specificallytheirfocusgroupEmpower,isseekingtocreatenewgreenjobsfor
itsemployeesandproduceacompetitiveproductforsaleinthefuelmarket.
TodeterminewhattypeofsystemwouldbebestforEPOCA,theyhadcertaincriteriafortheir
selectedprocess.Thesecriteriaincludedtheefficiencyandupgradabilityofthesystem,personneland
trainingrequirements,safety,andcosteffectiveness.ThecriterionsetbyEPOCAwerecategorizedand
thensub‐categorizedandputintoananalysismatrixtoevaluateeachproductionprocess.Eachcriterion
wasratedfrom1to5with5beingthebestpossibleonthescale.Inall,threeprocessesforproducing
biodieselwereanalyzed;thebatchprocess,continuousbatchprocess,andultrasonication.
Wheneachprocesswasputthroughtheanalysismatrix,thecontinuousbatchprocessisthe
recommendedprocesstoproducebiodieselforEPOCA.TheCBPscoredonaveragea3.5whenputinto
theanalysismatrix.Itparticularlyexcelledintheareasofcostflexibilityandupgradability.TheCBP,
beingessentiallyanupgradedbatchprocess,isabletohavelowpreliminarycosts,whicharemainly
dependentonthenumberandsizeoftanksusedfortheprocessallowingittobeconfiguredtoany
budget.Also,toincreaseproductivity,allcomponentsareabletobeupgradedasfundsbecome
available.
34
References
Adam,D.(2008,May12).WorldCO2levelsatrecordhigh,scientistswarn.TheGuardian.Retrieved
October13,2008,from
http://www.guardian.co.uk/environment/2008/may/12/climatechange.carbonemissions
AdvantagesofUsingbiodiesel.(n.d.).RetrievedOctober8,2008,from
http://www3.me.iastate.edu/biodiesel/Pages/biodiesel8.html
AgriculturalMarketingService.(n.d.).RetrievedOctober5,2008,fromhttp://ams.usda.gov
AmericanSolarEnergySociety.(n.d.).RetrievedOctober18,2008,fromhttp://ases.org
Baez,J.(2001,October21).Temperature.RetrievedOctober15,2008,from
http://math.ucr.edu/home/baez/temperature
Expansion.(n.d.).BiodieselExpansion:TheHistoricalBiodieselFuelPricesandItsEffects.Retrieved
October11,2008,fromhttp://www.12thalabama.com/2008/05/
Moreau,Tom.Biodeiselfromwastegrease?.RetrievedSeptember12,2008.From
http://www3.me.iastate.edu/biodiesel/Pages/biodiesel8.html
BiodieselIndustries.(n.d.).RetrievedOctober9,2008,from
http://www.biodieselindustries.com/bb/handling.html
Biodiesel.(n.d.).RetrievedOctober5,2008,fromwww.cyberlipid.org/glycer/biodiesel.htm
Dixon,D.D.,&Hayes,L.(1979).Solventbarrierpropertyforfluorinatedpolyethylene.JournalofApplied
PolymerScience,23(7),1907‐1913.RetrievedNovember11,2008,from
http://www3.interscience.wiley.com/journal/104025163/abstract?CRETRY=1&SRETRY=0
Engleman,E.G.(2002).HazardousMaterials:RevisiontoStandardsforInefectiousSubstances;Final
35
Rule.U.S.DepartmentofTransportations,67(157).RetrievedOctober19,2008,from
http://www.cdc.gov/od/ohs/pdffiles/DOTHazMat8‐14‐02.pdf
EnvironmentalDefenseFund.(n.d.).RetrievedOctober5,2008,fromhttp://edf.org
Gogate,P.R.,Kelkar,M.A.,Pandit,A.B.,UniversityofMumbai,Mantaga,Mumbai,InstituteofChemical
Technology.(2005).CavitationasanoveltoolforProcessIntensificationofBiodieselSynthesis.
RetrievedOctober23,2008,fromhttp://www.ncl‐india.org/camure/upload/mannullpaper‐
pandit‐camure2.doc
MarianKoshlandScienceMuseumoftheNationalAcademyofSciences.(n.d.).RetrievedOctober4,
2008,fromhttp://www.koshlandscience.org
NREL:AdvancedVehiclesandFuelsResearchHomePage.(n.d.).RetrievedNovember4,2008,from
http://www.nrel.gov/vehiclesandfuels/
SkepticalScience:ExaminingGlobalWarmingSkepticism.(n.d.).RetrievedOctober11,2008,from
http://www.skepticalscience.com
StoringBioDieselFuel.(2007,February28).RetrievedOctober10,2008,from
http://flashoffroad.com/Diesel/DieselFuel/bioStorage.html
ThomasNet.(2007,February28).HDPEResinsofferresistancetobio‐dieselfuels.RetrievedOctober8,
2008,fromnews.thomasnet.com/fullstory/548974
U.S.DepartmentofEnergy.(n.d.).Biodiesel:HandlingandUseGuidelines.RetrievedOctober8,2008,
fromhttp://www1.eere.energy.gov/biomass/pdfs/36182.pdf
U.S.EnvironmentalProtectionAgency.(n.d.).RetrievedOctober4,2008,fromhttp://epa.gov
36
UltrasonicTransesterificationofOilintoBiodiesel(HielscherUltrasonics).(n.d.).RetrievedNovember6,
2008,fromhttp://www.hielscher.com/ultrasonics/biodiesel_transesterification_01.htm
Zhang,Y.,Dube,M.A.,McLean,D.D.,&Kates,M.(2003).Biodieselproductionfromwastecookingoil:
Economicassessmentandsensitivityanalysis.BioresourceTechnology,90(2),229‐240.
RetrievedNovember13,2008,from
http://www.sciencedirect.com/science?_ob=ArticleURL&_udi=B6V24‐499F6F7‐
1&_user=74021&_rdoc=1&_fmt=&_orig=search&_sort=d&view=c&_version=1&_urlVersion=0
&_userid=74021&md5=48502d9405d089b1a6740b9e2bd9a75c
37
Appendix
38
39
