Biodiesel Safety and Best Management Practices for Small-Scale

7/29/2019 Biodiesel Safety and Best Management Practices for Small-Scale

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Bds Sa andBs ManamnPaccs Sma-ScaNncmmca Us andPducn

College of AgriCUltUrAl SCieNCeS


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SAfety geAr SUMMAryThe following gear should be on hand each time you

produce biodiesel:

Chemical-resistantgloves(butylrubberisbestfor

methanol and lye)

Chemistrygoggles(indirectvented)andfaceshield

Dustmaskorcartridgerespirator

Eyewashbottlewithsalinesolution

Smallspraybottlewithvinegarforneutralizinglyespills

Accesstorunningwater

Telephoneincaseofemergencyandemergency

telephone numbers

Fireextinguishers(ABCorCO2)

Absorbentmaterialandspill-containmentsupplies

CoNteNtSIntroduction ........................................................................... 1

FuelOptionsfromBiomassOilFeedstocks.........................1

UsingBiodieselBestManagementPracticesfor

Vehicles,Machinery,ColdWeather,andStorage.......... 2 TransitioningtoBiodiesel .............................................. 2

FuelStorage..................................................................... 2

BiodieselinVehicles/Machinery................................... 2

Cold-TemperatureIssues ................................................ 3

BiodieselShouldIMakeItMyself?.................................... 4

Economics ....................................................................... 4

FeedstockAvailability...................................................... 5

CompliancewithEnvironmentalRegulations ..............5

TimeCommitment ......................................................... 5

Messiness ......................................................................... 5

Chemical,Waste,andSafetyIssues ................................5

ResponsibilityforVehicle/EquipmentFailure .............5BestManagementPracticesforSmall-ScaleBiodiesel

Production....................................................................... 7

ProcessDescription......................................................... 7

RegulatoryIssues............................................................. 7

ProcessHazards,SafetyPrecautions,andHandlingIssues............................................................. 10

ChemicalHandling....................................................... 10

SafetyGearSummary.................................................... 12

ProcessSafetyandHandlingIssues ............................. 12

StorageIssues ....................................................................... 17

Spills............................................................................... 18

By-ProductHandlingandDisposal.............................. 19

TrackingEmissions:WhereDoestheMethanolGo?..22

MethanolRecovery....................................................... 24

BiodieselQualityTestMethods .................................... 26

Conclusions.......................................................................... 31

References ............................................................................ 31

Glossary................................................................................ 34

AppendixA:StraightVegetableOilConversions ..............36

AppendixB:BiodieselBatchStatusChecklist...................39


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IntroductIonThis publicain addrsss prcssing and say issus

assciad wih making bidisl ul. Bidisl is a

clan, rnwabl ul ha can b mad rm varius

bimass il dscks such as was vgabl il, yllw

gras, animal as, and virgin vgabl ils. Small-scal

bidisl prducin has bn grwing du highr ul

prics, a dsir r nrgy indpndnc, and inrs in

nvirnmnally rindly rnwabl ul prducin.

Although the biodiesel manuacturing process is airly

straightorward, there are several aspects o biodiesel

production that need careul attention to detail or a

productive, sae, and environmentally sound practice. First,

some chemicals used could pose serious risks to the operator

or to the environment, unless the proper precautions are

taken or storage, process saety, handling, ventilation,

and use. Second, disposal o glycerol by-product and waste

water generated rom biodiesel production could cause

environmental harm, unless approved practices are used.

Finally, operators need to pay close attention to the quality

o the biodiesel produced and proper storage to avoid costly

engine problems or excessive emissions during use.

Ms nhusiasic nwcmrs bidisl prducin

will nd ha succssully running a sa and rspnsibl

prain is n as asy as i lks. Prducin bidisl

n a small-scal carris inhrn risks, and carlss

prducrs ar likly hav mishaps. Whil h bvius

gal all prducrs shuld b minimiz misaks, i is

als impran knw hw dal wih hs misaks and

rspnd apprprialy. Knwldg, anin say, and

advancd planning ar h bs apprachs prvning

srius accidns.

Th bjciv his publicain is rviw sm

h accpd pracics assciad wih small-scal bidisl

prducin mak i a sa, nvirnmnally sund

pracic ha gnras a qualiy prduc. Prspciv

bidisl prducrs ar als ncuragd us his

inrmain as hy dcid whhr r n bgin making

bidisl. Fr h prparain his dcumn, w hav

slicid inpu rm a variy xprs including chmiss,

agrnmiss, nvirnmnal nginrs, rgulars, andducars in h ld small-scal bidisl prducin

and us. Plas n ha his bkl prvids rrncs

sa rgulains r Pnnsylvania; bidisl prducrs

in hr sas ar ncuragd chck wih hir sa

rgulars nsur ha hy ar in cmplianc wih all

rgulains. A glssary is prvidd a h nd h bkl

which dns rms usd hrughu h publicain.

Fuel optIons From BIomass oIl

FeedstocksWhil arly disl ngins dmnsrad an abiliy run

n crud plan-basd ils, mdrn disl ul sysms ar

dsignd r cincy and lw ngin missins and

burn uls a rlaivly lw viscsiy. A avrag ul ank

mpraurs, uncnvrd vgabl ils ar viscus

( hick) prprly burn in mdrn disl ngins

(spcially hs wih cmmn rail ul injcin sysms).

Ths wh wish run hir disl quipmn n raw

vgabl il, usd cking ils, animal as, r uls drivd

rm hs hav h llwing pins: (1) cnvr h il

bidisl, r (2) cnvr h disls ul sysm run

had ils as illusrad blw (Figur 1).

Note: Fr simpliciy, h gnral rm vgabl ils

is usd and includs virgin vgabl ils, usd cking

il, and rndrd animal as. Sm rsarchrs hav

xprimnd wih blnding uncnvrd vgabl ils

in disl ul as a ul addiiv r xndr. Whil sm

disls may lra lw prcnag (5 prcn) blnds

vgabl il in disl, his inrmain is ngin-spcic,

and highr-prcnag blnds ar n advisd. In a

dirn apprach, sm cmmrcially availabl prducs

prm blnding usd cking ils wih unladd gaslin

and addiivs rduc h viscsiy. This pracic is n

rcmmndd by h auhrs his bkl. Numrus

sudis by h Dparmn Enrgy and hrs hav

dmnsrad ha h us high-viscsiy uncnvrd

ils a lvls as lw as 10 prcn may caus ngin

war, injcr dpsi rmain, and prmaur nginailur. Ancdal rprs by disl srvic prsnnl als

rpr svral cass prblms wih injcr pumps and

hr pars linkd h us high-prcnag blnds

uncnvrd vgabl ils wih disl ul. Engin

manuacurrs may n hnr warranis i raw ils r any

hr ul prducs n ming ul qualiy spcicains

ar usd as ul.

FIgure 1

Vegetable Oil

Oil Conversion(Transesterification)

Vehicle Conversion

Biodiesel

StraightVegetable Oil


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Biicvi oi

Bidisl ul mus n b cnusd wih crud,

unranssrid vgabl il. Transsricain is a

chmical racin whrin il mlculs rac wih alchl

in h prsnc a bas caalys such as ly. This smwha-

rvrsibl racin rsuls in alkyl srs, als knwn as

bidisl, and a crud glycrl by-prduc. Th Amrican

Sciy r Tsing and Marials (ASTM), a cnsnsus

rganizain usrs, prducrs, and manuacurrs, clarlyspcis ul qualiy sandards r bidisl.

Sm ppl us h w rms sy-disl and

bidisl inrchangably. In crain rgins h Unid

Sa, sy-disl rrs crud syban il ha is lrd

and may b clarid, whil in hr rgins, bh rms

rr bidisl ul ha has bn prprly prcssd

(ranssrid) rm syban il. In indusry liraur,

FAME is an acrnym ha is n usd r Fay Acid Mhyl

Esrs (bidisl). In his dcumn, bidisl will rr nly

ranssrid il rm a variy dscks.

Bidisl ul can b burnd in any disl nginwihu majr mdicains h quipmn. Bidisl

blnds radily wih prlum disl. Ful blnds ar

rrrd by h prcnag bidisl in h mix (.g.,

B20 is 20 prcn bidisl). Bidisl ul can als b

blndd wih disl ul il r us in haing appliancs.

Ths wh wn disl quipmn undr warrany ar

advisd chck wih hir manuacurrs rgarding

rcmmndd prcnag limis r bidisl blnds.

Manuacurrs rquir ha any bidisl uls usd m

h ASTM D6751 spcicains r valid warranis.

si Vb oicvi dieqi

Th pin knwn as sraigh vgabl il (SVO)

cnvrsin rquirs alring h ul sysm h disl

ngin ha h vgabl il, hrby rducing is

viscsiy. Thr ar a numbr cmmrcially availabl kis,

as wll as hmmad cnvrsins, ms which uncin

n h sam basic principls. This apprach is dscribd

in Appndix A, bu rsarch is nging rviw pnial

ngin prblms and nvirnmnal cncrns (incrasd

missins). Alhugh his bkl dscribs say andnvirnmnal issus praining small-scal bidisl

prducin and us, sm h rgulains and say

inrmain will b usul SVO sysm usrs.

Bh bidisl and SVO sysms bgin wih vgabl

il. In h cas bidisl, h il is mdid sui h

ngin. In h cas SVO, h ul sysm h ngin is

mdid sui h il.

usIng BIodIeselBest management

practIces For VehIcles, machInery,

cold Weather, and storage

tiii Bii

Whnvr swiching bidisl r a bidisl blnd ul

in an ngin r srag ank ha had bn running n

prlum disl, i is rcmmndd mnir r chang

ul lrs n a mr rqun basis a las r h rs sixmnhs ar h ransiin. Bidisl is an xclln slvn

and, as such, i will radily disslv many h dpsis in

a disl ngin, ul injcrs, ul supply lins, and srag

anks ha hav accumulad vr h yars ngin

prain wih prlum disl. Cninu changing ul

lrs n an as-ndd basis unil h sysm has bn cland

h dpsis. Whn high-prcnag blnds bidisl ar

usd in rad vhicls, i is wis carry a spar ul lr and

h ls and knwldg chang i n h rad.

F sMs h sandard srag and handling prcdurs usd

r prlum disl can als b usd r bidisl. Th

ul shuld b srd in a clan, dry, dark nvirnmn.

Rcmmndd marials r srag anks includ

aluminum, sl, plyhyln, plyprpyln, and Tfn,

bu n cncr-lind srag anks. I pssibl, h srag

ank shuld n includ any cppr, brass, lad, in, zinc,

r rubbr ings i pssibl (pracically spaking, brass

ball valvs ar usd by many wih n majr ill c). Sinc

bidisl is an rganic liquid, h us an algacid r

ungicid addiiv is rcmmndd whnvr h ul issrd during warm wahr. Srag im r bidisl and

prlum disl shuld b limid six mnhs r bs

prrmanc. Rr h scins cvring Rgulary

Issus and Srag Issus r inrmain n rgulains

ha apply srag anks.

Bii i Vi/mi

Burning ASTM 6751 bidisl is a rcmmndd, accpd

pracic cnsisn wih many ngin warrany agrmns.

As discussd lar in his bkl, h bidisl ha yu

prduc may n m his sandard. Marginal-qualiybidisl may vnually ac ngin missins, lngviy,

and prrmanc.

Bidisl can b blndd wih prlum disl ul in

blnds up 20 prcn (B20) wih rlaivly w risks. Pnn

Sa is ding lng-rm sudis wih racrs using B100

(100 prcn) bidisl. Th pnial r prblms wih

using B100 is xpcd invlv h rubbr sals and hss

in h ul sysm. As mnind abv, bidisl is a br


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slvn han prlum disl and may sn r disslv

rubbr pars, spcially ldr rmulains rubbr.

Rplacing ld rubbr lins wih nwly manuacurd rubbr

is n sucin. Sinc bidisl is a gd slvn, i is

ncssary quickly wip any bidisl spills rm paind

suracs avid pain rmval.

Bidisl can als b usd in rsidnial il urnacs

r bilrs, spcially i i is blndd wih prlum ul

il. Th sam issus ha apply vhicl anks and sraganks apply hrh dpsis in h bm h ul

ank may disslv wih h addiin bidisl. I is

rcmmndd sar wih a lw cncnrain bidisl

rlaiv prlum disl, changing h ul lr mr

rqunly nsur ha any disslvd ank-bm sludg

is capurd by h ul lr. Ful pump sals ha ar mad

rubbr will hav h sam issus dgradain ha

vhicls and machinry will, paricularly a highr blnds.

Bidisl shuld b blndd wih prlum disl prir

lling h ul ank nsur adqua mixing. I his is

n pracical, a a minimum h bidisl shuld b addd h ank ar h prlum ul, as i is slighly dnsr

and sm blnding will ccur as i sls h bm

h ank. Sinc bidisl burns wih a clanr fam han

haing il, i may cnund fam-snsing cmpnns

in haing appliancs. Usrs wh wish xprimn

wih high-prcnag blnds ar advisd cnsul a

prssinal haing cnracr br ding s. S h

Rrncs scin r mr inrmain.

c-t I

Bidisl and is blnds wih prlum disl will cludand gl a highr mpraurs han nrmal winrizd

prlum disl ul. As mpraurs drp, wax-lik

crysals rm in h ul. Ths crysals will pnially

clg ul lrs r ul-lin inl scrns, causing salls r

ailur sar. Pluggd ul lrs may srain injcin

pumps, pssibly rducing h lngviy hs xpnsiv

cmpnns. Usrs ar advisd prpar r cld

mpraurs in advanc in rdr avid vhicl and

quipmn prblms assciad wih cludy r slidid

ul. Th prlum disl usd in cld climas shuld b

winrizd disl ul.A uls clud pin (CP) is h mpraur a which

i rs bgins appar cludy, as crysals sar rm. Th

pur pin (PP) is h minimum mpraur a which h

ul can b cnsidrd a liquidblw his mpraur

h ul will b ully glld. Th cld lr plugging pin

(CFPP) is usually clsly rlad h clud pin, hus

sing r clud pin may b h ms pracical way

prdic a uls winr prrmanc. Cmmrcial ul

prducrs ar rquird niy cusmrs a givn uls

pur characrisics, and small-scal prducrs ar advisd

b awar pur pins in h bidisl hy prduc. Th

rcn inrducin ulra-lw sulur ul (ULSF) maks

his mr impran, sinc arly indicains ar h high

ULSF can als cnribu h lw mpraur prblm.

Clud pin and pur pin bidisl will vary

accrding dsck. O h vgabl ils cmmnlyavailabl in h U.S., canla il is h bs r prducing

winr bidisl ul, wih a clud pin in h 20-

30-dgr rang (F). Sy bidisl ypically cluds arund

32 dgrs Fahrnhi (0 dgrs Clsius). Bidisl

mad rm animal as, allw, r hydrgnad (cramy)

vgabl ils will clud and gl a mpraurs abv

rzing, and hus hs uls prrm bs in suhrn

rgins r summrim.

Freezer Test

Small prducrs wh us ils rm mulipl surcs

ar advisd s ach bach bidisl ul r cld

wahr prrmanc. A simpl s using jars, a rzr,

and a hrmmr is civ drmin prpr

winr blnding ras. Blnds bidisl and winrizd

prlum disl ul varying prprins (.g, B10,

B20, B50) ar mad up in small jars and hn placd in h

rzr. By rqunly chcking h mpraur ach

jar, a prducr can rughly drmin h mpraur

a which cluding and glling will ccur r ach blnd.

Knwing h xpcd lw mpraur, usrs can hn

prdic which blnd will b rubl r. Exrm car musb akn n spill disl r bidisl blnds in a rzr

ha is usd r d srag. Us a plasic ub r scndary

cnainmn, and plac in a scur, lvl sp. D n lav

ul in rzr whr hrs may disurb i accidnally.

A rugh vrsin his s can b prrmd by

laving markd blndd jars ul in an udr,

unhad lcain during h winr. I is bs sar

blnding bidisl wih prlum disl cnsrvaivly wll

br winr prvn lr plugging in unxpcd cld

snaps.

Additives

Svral ul addiivs ar availabl r winrizing

prlum disl ul, and a handul ar spcically

dsignd winriz bidisl blnds. A 2005 sudy a h

Univrsiy Idah und svral cmmrcial bidisl

addiivs b civ a rducing h pur (gl) pin

blnds, bu hy had lil c n h pur pin B100.

Furhrmr, h addiivs did n signicanly rduc h


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clud pin (ky prvn lr plugging) bidisl

blnds, vn a svral ims h rcmmndd usag ras.

Sm individuals d rpr succssul rducin clud

pins wih varius uncnvninal addiivs, bu usrs ar

advisd s blnds br using in hir quipmn and

rr n h sid cauin.

Preparing for Winter Trouble

I is advisabl b amiliar wih h ul sysm in vhicls

and machinry using bidisl in cas any winr rubls

aris. I is always hlpul carry a spar ul lr and

h ls chang i, spcially in winr. I quipmn

salls du ul sarvain, xchanging h waxd lr

r a rsh n lld wih prlum disl may g i back

in srvic. A spar v-galln ank rsh winrizd

prlum disl (r krsn r -rad quipmn) can

b qui handy. I mpraurs drp unxpcdly blw

h clud pin bidisl in h quipmns ul ank,

adding rsh disl p h ank may hlp prvn

cluding and lr plugging. This is spcially civ i

h disl ul is srd in a had spac. Blck hars

ar civ a kping h ngin warm nugh sar,

bu i a gl layr rms in h ul ank, prblms will

prsis. Whn all ls ails, h vhicl can b wd a

had garag haw u. Fr mr inrmain n winr

prparains, s Rrncs.

Blending for the Cold Season

I is bs blnd bidisl wih winrizd prlum

disl ul (cu wih krsn by h ul disribur). Small

prducrs will ypically splash blnd by simply puring

h w uls in a ank a h dsird prprins.Bidisl will mix radily wih disl ul simply hrugh

h agiain gnrad by driving a vhicl. Fr sainary

anks, i is bs add bidisl n p prlum

disl, as bidisl is dnsr and will sl h bm,

blnding n is way dwn. Whn blnding, bh bidisl

and prlum disl shuld b a mpraurs abv h

bidisl clud pin, as xprinc has shwn ha uls

blndd a cld mpraurs may n say mixd. Fr

his rasn, small prducrs wrking in unhad shps

may wan blnd up a larg bach winr ul br

udr mpraurs drp in h la all. I bidislshuld clud r gl, i will nd b warmd wll abv

is clud pin ully disslv waxy crysals ha rmd a

lw mpraurs. N: Whn blnding uls, anks shuld

b grundd avid saic charg buildup (s Chmical

Handling).

BIodIeselshould I make It myselF?W bgin his scin assuming ha yu ar alrady

cmmid using bidisl, and ar dciding i yu

shuld mak i yursl. Making bidisl ul yursl

rs many challngs. Fr sm ppl, h njymn

h prcss and h rward making yur wn ul

uwigh h challngs. This is r ach prsn

drmin. Whil cnvring n galln il in bidis

is simpl and airly asy larn, prcssing and nishing

hundrds gallns was ryr il in ul will prsn

nw challngs wih ach dirn bach il. Rading

bcm amiliar wih h nr dails prcssing,

say prcls, and nw dvlpmns in qualiy sing

is ssnial. This scin prvids sm hings cnsidr

whn dciding i yu wan prcd wih small-scal

prducin bidisl.

ei

I is cmmn r nw prducrs undrsima h im

hy will invs in h myriad aspcs ul prducin.An analysis can b prrmd h cs inpus vrsus

h rsulan valu h ul prducd. Whhr r n

labr cs will b accund r dpnds n h individual

prducin aciliy, and whhr bidisl is mad as a

hbby, r in plac hr incm-gnraing wrk.

Css cnsidr in drmining h cnmics small-

scal bidisl prducin includ:

Capitalinvestmentinequipmentthismayinclude

purchasing nw quipmn and acquiring a lcain

prduc and sr h bidisl. Capial css mayb ngligibl i prducin primarily uss rcycld

marials in an xising wll-vnilad spac.

Feedstockacquisitionprocuringtheoil,whetherfree

r pickup r purchasd

Chemicalsthesemaybeboughtinbulkorsmall

quaniis

Disposalcostofby-products

Permitfees

Electricity/energythisincludestheelectricitytorun

h prcss, bu may als includ ha and vnilainr h aciliy

Laboryoumayormaynotchoosetoincludethisin

yur css

Sinc css and availabiliy dscks vary, yur cs

shuld b cmpard qualiy cmmrcial bidisl ul

br dciding mak yur wn ul.


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F avibii

Each nished gallon o biodiesel produced will require

slightly over one gallon o eedstock, either new vegetable

oil or ltered waste ryer oil rom restaurants. Prospective

biodiesel producers should consider the amount o uel

they hope to produce, and then be certain that they will be

able to obtain and handle the necessary eedstock oil on a

regular basis. As production volumes increase, the logistics

o collecting large amounts o waste ryer oil may becomemore cumbersome. In addition, as more people produce

biodiesel, there may be competition or waste ryer oils.

Lastly, it should be noted that working with used cooking oil

is somewhat more complicated than virgin oils, due to the

varying acidity, moisture content, and quality o used oil.

ci wi evi ri

Bidisl prducin aciliis may b subjc rgulain

by h Dparmn Envirnmnal Prcin (PADEP)

and hr niis, dpnding n hir siz and cmmrcial

saus. Currnly, small-scal, nncmmrcial aciliisar xmp rm PADEP prmiing, bu will b subjc

discrinary nrcmn i prblms r cmplains

aris. Ohr aspcs small-scal bidisl prducin

may b rgulad. A summary h rgulains which

may apply yur aciliy is givn in Rgulary Issus. W

srngly ncurag anyn wh is cnsidring small-scal

bidisl prducin carully rviw h rgulary

rquirmns in rdr avid any vilains h law.

ti ci

Whil bidisl ha is mad rm r usd cking ilhas a rducd marials cs, h im cmmimn r

prcssing shuld n b vrlkd. T rspnsibly

pra a small-scal bidisl aciliy, yu shuld allw

im r all h llwing:

Fabricationandmaintenanceofbiodieselequipment

Oilcollection

Securingchemicals

Fuelprocessing

Methanolrecovery

Waterwashingofthefuelorothernishingtechniques

Qualitytesting

Disposalofwasteproducts

Ths wh d n hav ampl im in hir schdul

r a nw prjc ar n advisd bgin bidisl

prcssing purly as a mans saving mny.

mi

Dspi carul handling, bidisl prcssing will

cmmnly rsul in sm grasy sps n h drivway

r in h arm yard. Cllcins il jugs and barrls

can bcm unsighly unlss sricly managd. Laking r

sping ccurs in sm plasic jugs vr im. In addiin,

hr may b an bjcinabl dr assciad wih spild

usd ryr il. Vhicls usd cllc ryr il, buildings

usd r husing bidisl gar, and clhing wrn duringprcssing ar als likly b acd by sicky ryr il

vr im. Kping h wrk ara clan adds labr cs

h prducin h ul, bu is a wrhwhil say

pracic.

ci, W, sf I

Chemical Exposure and Safety

Mhanl (a fammabl, xic alchl) and ly (a crrsiv,

causic bas) ar w hazardus chmicals rquird

cnvr vgabl il in bidisl. Ovrxpsur

mhanl can caus nurlgical damag and hrhalh prblms; and i prsns a srius r risk.

Ly can caus skin and lung irriain. Bh mhanl

and ly can caus y damag r blindnss. Rigrus

prcauins ar ncssary avid prsnal pisning,

r, and cnaminain sil and war rsurcs. Br

bginning a bidisl prjc, plas cnsidr whhr r

n yu can rspnsibly llw h say prcls ulind

in Prcss Hazards, Say Prcauins, and Handling

Issus.

Handling of By-Products

Bidisl prcssrs gnra subsanial quaniis

crud glycrl by-prduc (abu n galln was

prduc cnaining glycrl r vry v gallns

bidisl prducd). Ms prcssrs als us war r ul

puricain, and may gnra as much as hr gallns

was war r ach galln ul prducd. Bh

glycrl and was war rquir handling and dispsal

cnsidrain (s By-Prduc Handling and Dispsal r

urhr inrmain).

Responsibility for Vehicle/Equipment Failure

Th mmn ha a small prducr purs h rsgalln hmmad ul in a ul ank, ha prducr

aks rspnsibiliy r h uur prrmanc h

quipmn in qusin. Whil hr ar husands

xampls wrldwid small prducrs succssully

pwring disl quipmn wih hmmad ul, usrs

shuld als undrsand ha prblms can and d ccur.

Carul anin prducin chmisry and ul-qualiy


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6

FIgure 2

Vegetable OilStorage Tank

Good Oil

Bad Oilto CompostRenderer

Methanol Plus Catalyst,Mixed in Tank

CheckValve

Pump InletManifold

Circulation Pump

Biodiesel out

Glycerol Drain

For Safety, Drain Glycerol via Tubingto Minimize Methanol Exposure

Electric Heat

MainReactorTank

Pressure Relief Valve

Air Vent

Vents toOutside

Warm Water Outlet:to wash Line

Cold Water Inlet

Recovered Methanol

Filter

To Equipment

Pump

FuelStorageTank

Dryer TankWash Tank

BiodieselInlet

Water Inlet

Dryer TankPump

Water Drain to Treatment

Biodiesel Drainto Dryer Tank

(Sealed and

Insulated,Rated for250 F+)

to Wash

MethanolCondensor

Example of BiodieselProcess Line

= Ball Valve = Other ValveKey

Not to Scale, Some Features OmittedOriginal by Matt Steiman, 2007

Vents toOutside

Vent

Biodiesel

Wash Water


9/44

7

sing is a mus, as is car in dvlping clima-spcic

winr blnds. A basic undrsanding h mchanics

disl quipmn and a radinss addrss any ul

sysm prblms ha may aris ar advisabl. Small-scal

prducrs ar cauind dvlp hir prducin skills

whil using hir ul in ldr, inxpnsiv quipmn,

br running hir bidisl in nwr, mr xpnsiv,

and ssnial quipmn. Hmmad (nn-ASTM crid)

bidisl ul shuld n b usd in quipmn ha isundr warrany i yu xpc h warrany rmain valid.

Best management practIces For small-

scale BIodIesel productIonWha llws is a summary pracics r small-scal

bidisl prducin dvlpd wih h gal prducing

high-qualiy bidisl ul in a mannr ha is sa,

nvirnmnally rspnsibl, and labr cin. This

scin is n man as a hw- manual, bu insad

a summary rgulains and guidlins r small-scalprducin in Pnnsylvania. S Rrncs nd

inrmain n hw prduc bidisl.

p dii

Whil n cmmnly llwd vrsin h bidisl

prcss is prsnd hr (Figur 2), hr ar a muliud

alrnaiv mhds hrugh which small prducrs

succssully ransrm dsck ils in qualiy bidisl.

Prducrs ar ncuragd say up--da wih Inrn

and prind rsurcs, as nw pracics r sa and

cin prcssing ar cnsanly bing dvisd by hsmall-scal prducin cmmuniy.

Simplid Ovrviw Prcssing Sps

1. Cllc dsck: was il rm rsaurans, prssd il

rm ilsd crps, rndr animal as, rap gras, c.

2. Checkoilforwatercontent(seeBiodieselQuality

Ts Mhds) and d-war il i ncssary. (Sling

collectedoilsinlargebulktanks/drums,thendrawing

oilforprocessingfromthetopofthetank/drummay

b sucin in warmr wahr.)

3. Filr il rmv d paricls and dbris.4. Fill prcssing quipmn wih il and bgin haing.

5. Ts il r r-ay acid cnn via irain

drmin h amun caalys (NaOH ly r KOH)

tobeusedperliterofoil(seeBiodieselQualityTest

Mhds).

6. Mak a mini bach wih h had il (500 mL r

1 lir) s h accuracy h rcip bing usd

br prcding a larg bach. Masn jars r

plasic sda bls mak chap and civ s bach

vssls, prvidd hy hav igh-ing lids.

7. Whn il has rachd h racin mpraur 120

130 dgrs Fahrnhi (50 55 dgrs Clsius),

prcd mix h larg bach using h rcip rm a

succssul s bach. Carully mix ly wih mhanl,

add chmicals il, mix r up w hurs, and hn

allw glycrl by-prduc sl.8. Mak accura rcrds all variabls in ach bach

ul: il surc, mixing im, mpraur, quaniis

racans, any hr prcssing variabls.

9. Drain glycrl by-prduc and labl r urhr

prcssing, mprary srag, r dispsal. Th glycr

will cnain signican mhanl and shuld b

handld as such (fammabl and xic).

10. Rcvr xcss mhanl rm raw bidisl. I

mhanl is n rcvrd rm bidisl, h raw ul

shuld b rad as i i wr mhanl (fammabl

and xic).

11. Pump bidisl wash anks and wash.

12. Allw war sl u vr svral days r dry

bidisl via aciv drying.

13. Pump hrugh a lr ul srag barrls.

14. Ts ul r qualiy paramrs and cmpar wih

prcssing rcrds.

15. Rcvr mhanl rm glycrl nc sucin

quaniis ar n hand.

16. Disps glycrl and wash war in a sa and

rspnsibl mannr (s By-prduc Handling and

Dispsal).

r I

Thr ar rgulains, bh sa and dral, which

cvr varius aspcs bidisl prducin, srag,

and dispsal. Knwldg which rgulains apply

yu is ssnial. Furhrmr, yu may b subjc

spcic rquirmns rm yur lcal municipaliy, s i is

impran chck h lcal rgulains and rdinancs.

Yu shuld chck wih yur lcal Cuny Emrgncy

Managmn Agncy, r cials, and yur lcal

Dparmn Envirnmnal Prcin c prir

iniiaing any chmical srag, ransprain, r handling

pracics n yur prmiss, and br dispsing any

was marials. Th rgulains chang rqunly r

hs yps aciviis.

I is criical raliz ha yur gals and hs h

rgulars ar h sam prc h nvirnmn, yur


10/44

8

halh, yur prpry, and h gnral public. Dn b

araid rpr a spill r ask r assisanc.

Th llwing lis givs a summary dral and

sa rquirmns which may apply yur aciliy. Th

acrnyms r h rgulary agncis ar dnd blw.

Cnac inrmain r ach agncy is lisd in Rrncs,

as is h Wb addrss r Pnnsylvanias rgulains.

EnvironmentalProtectionAgency(EPA)

OccupationalSafetyandHealthAdministration(OSHA)

PennsylvaniaDepartmentofEnvironmentalProtection

(PADEP)

PennsylvaniaDepartmentofLaborandIndustry

(PADL&I)

PennsylvaniaDepartmentofRevenue(PAREV)

Issues and Regulations That May Apply

Bidisl prducin rm usd cking ils r hr usd

animal as

PADEPrequiresacommercialprocessor(anentity

ha prducs bidisl r sal) usd cking il,

yllw gras, ils and as rm rndring plans, c.,

hav a gnral prmi r bncial us undr h

rsidual was rgulains. Farm r hm prducin

bidisl ha is n r sal is xmp rm hs

rquirmns.

Srag anks

EPArequiresaSpillPrevention,Control,and

Cunrmasurs Plan r abvgrund srag ils

(any yp including vgabl, prlum, animal as,c.) 1,320 gallns r mr r undrgrund srag

40,000 gallns r mr (Til 40, Cd Fdral

Rgulains, Par 112).

PADEPregulatesabovegroundstoragetanksthat

cnain hazardus subsancs (such as mhanl) 250

gallns r mr r undrgrund srag anks 110

gallns r mr (Til 25 Pa. Cd Chapr 245). Thy

als rgula srag anks a rsidncs r arms ha

cnain bidisl r blnds bidisl and prlum

disl i hy cnain mr han 1,100 gallns. I anks

cnain was cking ils which wr gnrad

by a rsidnc, municipal building, insiuin, r

cmmrcial sablishmn (such as a rsauran) and

h bidisl is mad by a small-scal nncmmrcial

prducr, h Municipal Was Managmn srag

rgulains apply. Ths rquir ha h abvgrund

anks b prprly cnsrucd and hav scndary

cnainmn. Undrgrund anks mus b chckd

annually r laks. (Til 25 Pa. Cd 285.122). I h

il was gnrad by a d prcssing plan r was an

agriculural was prduc such as n-arm rndrings,

hn Rsidual Was Managmn srag rgulains

apply. Ths ank rgulains ar cnsidrably mr

cmplx and bidisl prducrs ar advisd cnac

h DEP (Til 25 Pa. Cd 299.122).

PADL&Iregulatesstoragetanksof30gallonsormore

ha cnain blnds B60 r lwr (fashpin 200dgrs Fahrnhi [93 dgrs Clsius] r lwr).

Tanks ha cnain uls usd r haing r gnrars

ha ar lss han 3,000 gallns ar xmpd. (Note:

In Allghny and Philadlphia cunis, his rgulain

is undr h jurisdicin h cuny r marshal, n

PADL&I). S Til 37 Pa. Cd Chaprs 11, 13, and 14

Oil and hazardus-marial srag

PADEPmayrequireaPreparedness,Prevention,and

ContingencyPlanifhazardousmaterialsand/oroil

ar srd in quaniis 55 gallns r mr wihu

scndary cnainmn and hy hav h pssibiliy

nring h nvirnmn (sil, srmwar drains,

surac war, c.) i spilld r lakd (s Rrncs

r dail).

Oil ransprain

Usedcookingoilthathasbeengeneratedbya

rsidnc, municipal building, insiuin, r

cmmrcial sablishmn (such as a rsauran)

mus b ransprd as Municipal Was (25 Pa. Cd

285.201). Usd ils gnrad by d-prcssing plans

mus m h sam rquirmns bu mus b labldRsidual Was (25 Pa. Cd 299.201). S h

Srag Issus scin r mr dails.

Say

OSHAregulatesemployeesafetyandprovides

sandards r wrkplac hazards.

Oil and hazardus-subsanc spills

EPAregulatesspillsof40gallonsofoilormore(this

includs usd cking il and bidisl) warways

r whr a visibl shn is prsn; spills his siz

mus b rprd h Nainal Rspns Cnr

(Til 40, Cd Fdral Rgulains, Par 110).

Spills mhanl ha xcd 5,000 lbs (758 gallns)

and passium hydrxid r sdium hydrxid ha

xcd 1,000 lbs mus als b rprd h Nainal

Rspns Cnr (Til 40 Cd Fdral Rgulains

Par 302).


11/44

9

PADEPregulatesspillsofhazardoussubstancesandoil

ha culd pllu h wars h Cmmnwalh.

This is inrprd includ grundwar and surac

war; all spills mus b rprd h rginal PADEP

c. Prvnin spills rm was marials in

srag (including cnainrs) ar rgulad by Til 25

Pa. Cd 285.121

Air qualiy

PADEPregulatesairqualityandrequiresaplan

apprval r aciliis ha will hav mhanl missins

n n r mr (s h Tracking Emissins scin

r a discussin mhanl missins). A Rqus

r Drminain (RFD) can b mad hrugh h

PADEPs Wb si (s h Rrncs scin). In

addiin, n maldrs can lav h prpry (Til 25

Pa. Cd Chapr 127).

Dispsal was prducs

PADEPregulatesthewasteproductsgeneratedbythe

bidisl prcss as a las rsidual wass, and in smcass, such as pur mhanl, as hazardus wass. Any

was ha ms h characrisics a hazardus was

undr Til 25 Pa. Cd 261.20 has b handld as a

hazardus was. Th was gnrar is rspnsibl r

apprpria chmical sing and rcrdkping.

Wash War

PADEPdoesnotallowthistobedischargedinto

n-l spic sysms r in srm swrs. I is a

las a rsidual was and may b a hazardus was,

dpnding upn is characrisics (s abv).Dispsal a municipal waswar ramn plan

mus b apprvd by h praing agncy ha

aciliy.

Localmunicipalitiesmayregulatedisposalofwash

wars h ramn plan; bs managmn

pracics nuraliz his wash war ar givn in h

By-Prduc Handling and Dispsal scin and mus b

apprvd by h ramn plan prir dispsal.

Glycrl

PADEPdoesnotallowthismaterialtobedisposedofby ihr land applicain r cmpsing i i cnains

mhanl. I is rgulad as a rsidual was r pssibly

a hazardus was, pnding characrisic s rsuls

undr Til 25 Pa. Cd 261.20, and mus b dispsd

a a prmid landll pnding s rsuls and apprval

rm h Landll Opraing Auhriy and h Was

Managmn Faciliis Prmiing Scin h

Rginal PADEP Oc. I h mhanl has bn

rmvd, h glycrl may b cmpsd r usd as a

dus supprssan n rads, bu a prmi rm h DEP

is rquird. S By-prducs Handling and Dispsal, r

urhr discussin.

Mhanl, Ly

EPAandPADEPregulatethesematerialsashazardous

wass nc hy ar drmind b wass (Note:

This is nothushld hazardus was, i is rm a

chmical racin prducing cmbusibl ul, and

has nhing d wih a nrmal hushld aciviy).

S Prcss Hazards, Say Prcauins, and Handling

Issus r prpr srag and dispsal hazardus

wass.

Bad vgabl ils

PADEPregulatesthisasaresidualwaste.Itmaybe

dispsd in a prmid landll (wih apprval

rm h Landll Opraing Auhriy) r cmpsd.

Cnsul h Was Managmn Faciliis PrmiingScin h Rginal PADEP Oc.

Public Highway Rad Tax

PAREVregulatestheuseofanyfuelusedinadiesel

ngin n h rad. I a prducr maks lss han 1,000

gallns bidisl pr yar r rad us, h rad ax

is prpaid r 1,000 gallns and rducd a h nd

h yar basd n h acual vlum prducd. I 1,000

gallns r mr ar prducd pr yar, h prducr

mus b licnsd and bndd and pay mnhly s.

Fdral Excis Tax

TheIRSrequiresthatbiodieselproducers(including

small-scal prducin r prsnal us) rgisr (Frm

637), rpr, and pay xcis ax r bidisl ha is

prducd r us in n-rad rgisrd mr vhicls.

Th vhicl prar is liabl r h dral xcis ax

of$0.244/gallonontheB100fuelusingForm720.A

bidisl prducr may claim h bidisl blndrs

crdi i h ul is mixd wih a las 0.01% disl

and/ormayclaimthebiodieselproducerscredit.

Fr bh hs crdis h bidisl mus m h

ASTM rquirmn D6751 and h rquirmns

h Clan Air Ac. In rdr m h Clan Air

Ac rquirmns, a small prducr wuld hav

jin h Nain Bidisl Bard, which is likly

cs prhibiiv r ms small-scal nn-cmmrcial

prducrs. Ths bidisl ul crdis may b claimd

using Frm 8864.


12/44

10

p hz, sf pi, hiI

Say shuld b h p pririy in any bidisl prain,

abv all hr gals. Accidns invlving chmicals and r

larg vlums vgabl il, bidisl, r by-prducs can

caus injury, lss li, prpry damag, r nvirnmnal

cnaminain. Ths wh hp avid uur

gvrnmn prhibiin small-scal bidisl prducin

wuld d wll cnsidr ha rgulain n llwsaccidns. By llwing bs pracics r say, small

prducrs as a grup will cninu rmain in cmplianc

wih cials rspnsibl r public and nvirnmnal

halh.

A cmprhnsiv apprach say bgins wih a

whl-sysm cnsidrain all pnial aras r risk,

llwd by hrugh plans r accidn prvnin. As a

backup, prparains shuld als b mad r rspns

any accidn ha may ccur.

As a gnral rul, usrs shuld bain and rad a cpy

h Marial Say Daa Sh (MSDS) r mhanl andly, and b amiliar wih h say cnsidrains r ach

chmical. A bs pracic is cra a clarly labld

say sain wihin h prcssing aciliy, whr h

MSDSs ar kp radily accssibl. This will allw wrkrs

and r r mrgncy prsnnl radily lca chmical

say inrmain in cas an accidn.

I is rcmmndd ha small-scal prducrs cnac

hir lcal r sain advis hm h prcssing and

chmical srag ha may b ccurring n si. This will

srv warn say prsnnl r hir prcin in cas

a r, as wll as giv r cials a chanc hlp small-scal prducrs addrss any pnial aras cncrn.

Ths wh ar unwilling invi r say prsnnl

hir aciliy wuld d wll cnsidr hir abiliy

rspnsibly prduc bidisl wihu incidn.

Accidns nd ccur whn prars ar ird,

disracd, r hurrid. Prducrs ar advisd wrk

slwly and hughully, and avid juggling many

asks a nc in h bidisl plan. Tmprary rigging

quipmn and shrcus ar high-risk bhavirs ha n

lad unrsn cnsquncs.

Chemical Handling

Mhanl is xic and mus b handld and usd in a

wll-vnilad ara. Inhalain r ingsin mhanl

can b vry harmul a highr cncnrains and can

lad dah r blindnss. I is spcially damaging

h ys; say gggls, chmical-rsisan clhing, and

glvs mus b wrn whnvr handling h marial. I

cncnrains in h air xcd 200 ppm, air-supplid

rspirars ar rquird, prrably wih a ull-ac mask.

(Canisr rspirars ar n civ r rgular us in

mhanl vaprs). Th lvl a which h dr mhanl

is prcpibl is grar han 200 ppm. Thus, i n smlls

mhanl in h prcssing aciliy, unhalhy prsnal

xpsur is alrady ccurring. Prducrs ar advisd

alr any prcssing aciviy ha rsuls in prcpibl

mhanl drs.

Thr hav bn many insancs whr mhanlwas ingsd purpsly bcaus is mildly inxicaing

c (much lik hanl). Ingsin has ld numrus

cass dah r blindnss, and prcauins mus b akn

kp his chmical away rm childrn and animals.

Mhanl ingsin, inhalain high cncnrains,

and any cnac wih h ys rquirs immdia mdical

anin. Shr-rm xpsur mhanl vapr can

irria h ys, ns and hra, and caus hadach,

nausa, vmiing, dizzinss, and rubl brahing.

Ohr cmmn sympms drunknnss, such as

lighhaddnss, giddinss, blurrd visin, and diladpupils, migh als appar. Th sympms dpnd n h

lvl and lngh xpsur and can vary rm prsn

prsn.

Mhanl will radily disslv in war and i rlasd

wihu prpr ramn, can g in h war abl.

Mhanl is fammabl and prsns a r hazard. I

is havir han air and can ravl a subsanial disanc

nd an igniin surc wih subsqun fashback h

prcssing uni r mhanl srag ank. Mhanls fash

pin is a rahr lw 52 dgrs Fahrnhi (11 dgrs

Clsius) which is h pin whrby sucin vapr isrlasd rm a pnially fammabl mixur. A

bidisl prcssing mpraurs (110 140 dgrs

Fahrnhi), hr is nugh mhanl vapr gnrad

susain a srius r i air is allwd mix wih h

mhanl.

Sdium hydrxid (NaOH) and passium hydrxid

(KOH) ar crrsiv and may b aal i ingsd. (Ths

chmicals ar bh rrrd as ly r caalys

lswhr in his bkl.) Skin cnac can caus svr

burns and h ara acd shuld b hrughly fushd

wih war r a dilu vingar sluin. Inhalain hslid NaOH r KOH is pssibl i h marial is rducd

dus-sizd paricls. Any hs siuains is criical,

rquiring immdia mdical anin. Sdium and

passium hydrxid mus b srd away rm war sinc

war will inhibi h bidisl racin as wll as caus ha

rlas du mixing, which can pnially caus a r in

adjacn marial. NaOH, KOH, and cncnrad sluin


13/44

11

shuld nvr cnac aluminum as hy will cra xplsiv

hydrgn gas.

Prpr say gar r wrking wih NaOH r KOH

includs lbw-lngh glvs, chmical say gggls, a

dus mask r rspirar, lng pans, and shs. An ywash

stationand/oremergencyshowerwithin25feetofthe

wrkspac ar als highly rcmmndd. (A hmmad

ywash sain can b as simpl as a ddicad gardn hs

r auc ha runs a cnsan, gnl sram war upin h ys. Dsign r hands-r prain s ha an

acd prsn can us h hands kp ys pn whil

fushing.)

Whn masuring anyhing bu vry small quaniis

NaOH r KOH, waring a dus mask r carridg rspirar

is vry impran prvn inhalain causic paricls.

A spray bl vingar is handy r nuralizing any

small rsidual caalys spills in h wrkplac. Fin paricls

NaOH r KOH will prduc hls in clhing, hus

a prciv aprn r jumpsui is als advisd. I is als

hlpul r ach prsn wrking in h bidisl shp kp a spar chang clhs n hand, s ha accidnally

cnaminad clhing can b quickly shd i ndd.

Sdium mhxid r passium mhxid is mad

during h prcss by cmbining h mhanl and sdium

hydrxid. I has many h sam crrsiv and xic

characrisics as mhanl and sdium hydrxid, and

shuld b handld similarly. Pur sdium r passium

mhxid is n vry sabl and can igni n cnac wih

war r mis air.

Bdg d Grdg

Saic lcriciy can build up whn fuid fws hrugh

a pip r rm an pning in a ank. Bnding and

grunding prvns saic lcriciy rm causing a spark

ha culd igni vaprs rm a fammabl liquid (Figur 3)

Bnding physically cnncs w cnduciv bjcs

ghr wih a wir limina h dirnc in saic

charg pnial bwn hm. A bnd wir mus b

prvidd unlss a mallic pah bwn hm is hrwisprsn.

A grounding wire eliminates a dierence in static charge

potential between conductive objects and the ground.

Although bonding will eliminate a dierence in potential

between objects, it will not eliminate a dierence in potential

between these objects and earth unless one o the objects is

connected to earth with a ground wire (Figure 4).

Gnral Fir Say: N fams, smking r sparks anywhr

nar h prducin ara.

Sps CmbsBidisl prducin will ruinly prduc rags saurad

wih il r bidisl. I is als cmmn (bu n advisd) r

sawdus r hr brus marials usd as an absrbn

r spilld bidisl r vgabl il. Ths marials

prsn an inhrn r risk, as ily rags r sawdus can

asily spnanusly cmbus. In 2007, a Pnnsylvania barn

burnd h grund whn sawdus sakd wih vgabl

il caugh r n a sunny day. Ths marials mus n

b allwd accumula in r arund h wrkspac,

including in pn rash cans.

Oily rags shuld b kp in an air-igh mal cnainr,a buck war, r sald in vacuad plasic bags and

prprly dispsd in h rash. Fr liquid shuld b

squzd in an apprpria cnainr br dispsal

saurad rags. Whn dispsing saurad sawdus in a

dumpsr, b sur scar h marial avid any pils

ha may cmbus and caus a dumpsr r.

FIgure 3

FIgure 4

Common Ground Line

Ground Wire

Bonding Wire

Ground

GroundWire

Bond Wire

Ground

+ + + + + +

Bond Wire


14/44

12

Elcrical quipmn shuld b insalld by qualid

srvic prsnnl in accrdanc wih h nainal lcrical

cd and lcal rgulains. Tmprary rigging lcrical

quipmn is inhrnly dangrus and pss a srius

r risk. Haing lmns usd in prcssing ul shuld

b rgulad by apprpria hrmsas. Car shuld b

akn whn running pwr havy lcrical lads (such

as haing lmns) hrugh xnsin crds, s ha h

amprag r waag raing is n xcdd. I an lcricalcrd vr ls warm, i is vrladd and shuld b

unpluggd immdialy. Whn in dub, cnsul a qualid

lcrician.

Fir xinguishrs shuld b cnvninly lcad

hrughu h bidisl shp, and all usrs shuld b

amiliar wih hir prain. Avid blcking accss

xinguishrs wih clur r quipmn. Rmmbr h

acrnym PASS:

Pull h pin rm h r xinguishr

Aim h nzzl a h bas h r

Squz h riggr dvic

Swp rm sid sid h fam as yu xinguish

h r

A wny-pund ABC r xinguishr is

rcmmndd. I is a gd ida run ccasinal r

drills in h bidisl shp b prpard in cas an

acual mrgncy.

Safety Gear Summary

Th llwing gar shuld b n hand ach im yu brw

bidisl:

Chemical-resistantgloves(butylrubberisbestfor

mhanl and ly)

Chemistrygoggles(indirectvented)

Faceshield

Dustmaskorcartridgerespirator

Plumbedeyewashstation

Smallspraybottlewithvinegarforneutralizinglyespills

Accesstorunningwater

Telephoneincaseofemergencyandemergency

lphn numbrs

Fireextinguishers(20-lbABC)

Absorbentmaterialandspill-containmentsupplies

Process Safety and Handling Issues

Th Prdc Fcly

An idal spac r bidisl prducin will b wll-

vnilad y prcd rm wahr, and lckabl

prvn unraind ppl rm accssing chmicals and

quipmn. Adqua vnilain is an abslu mus du

srius halh hazards assciad wih mhanl ums

and ly dus. Vnilain can b prvidd mchanically,

via ans r chmical um hds, r by wrking udrsin h pn air. Srag spac r vgabl il, chmicals,

and prcssing gar shuld b ampl, and shuld n

cramp h wrking spac. Elcrical and war srvic ar

als rquird r ms prcssing sysms. A scndary

cnainmn sysm is advisabl in cas larg spills il,

bidisl, wash war, c.

A bs pracic is hav a spara spac ddicad

bidisl prducin, apar rm hr buildings ha

srv mulipl purpss. Bidisl prcssing in xising

muli-us buildings risks h lss asss in cas an

unrsn r r hr accidn. Usrs ar cauind absluly avid prducing bidisl in quaniy insid hir

prsnal rsidncs. Making bidisl insid a prducin

grnhus r livsck barn is als n advisd. Firs du

bidisl prducin may n b cvrd by hm r

arm insuranc plicis.

A ypical sluin r small-scal prducrs wuld nail

rcing an apprprialy sizd shd apar rm hr

buildings n h prpry. Inxpnsiv mdular mal

buildings varius sizs (such as hs sld as carprs)

ar nw cmmnly availabl hrughu Pnnsylvania.

Such buildings, whn quippd wih rracabl walls and

drs, wuld mak an idal si r small-scal bidisl

prducin. I is ssnial ha h aciliy n b lcad

immdialy adjacn warways ha culd b impacd

by spills chmicals, il, r bidisl.

A gd prcssing say plan sars wih a schmaic

fw char r h prpsd aciliy. Whr and hw will ly

and mhanl b srd and in wha quaniy? Hw will hy

b handld? Whr will vgabl il nr h building and

whr will i b srd? Hw will h marials invlvd in

varius prcssing sps mv hrugh h building? Hw

will ul and by-prducs xi h aciliy and whr will hy

b srd? B sur n h lcain say gar. Onc

a schmaic is mad, i can b applid h physical spac

undr cnsidrain r bidisl prducin.

Prcssg Eqpm

All h prblms assciad wih prcssing bidisl can

b handld wih a prprly nginrd dsign. Hwvr,


15/44

13

sm Wb sis suggs ha yu can build smhing

wih whas lying arund h hus. This can b vry

dangrus and shuld b avidd. Plas cnsul wih

xprincd bidisl prducrs r indusrial prsnnl

whn dsigning yur aciliy.

Whil hr ar a wid variy prcssr dsigns

ha will civly cnvr vgabl il in bidisl, r

sa and nrgy cin prducin, a clsd sysm ha

minimizs ppruniis r scap mhanl vaprsin h wrkspac r nvirnmn mus b usd. Alhugh

arly bks n bidisl ppularizd h us pn-

p barrls r mixing il wih mhanl and ly, hs

irrspnsibl dsigns rsul in incrasd r risk, incrasd

wrkr mhanl xpsur, and rducd ul qualiy

du vaprain mhanl rm h racin ank.

Addiinally, any puring larg quaniis mhanl r

mixurs ha cnain mhanl shuld b avidd in h

prcss dsign. Fr his rasn, a clsd sysm, whrin

il, chmicals, and nd prducs can b saly ransrrd

using pumps, ubing, and valvs is idal. Us dvics wihsparking lcric mrs, such as drills r pain mixrs, nar

pn cnainrs mhanl als prsns a r risk and

mus b avidd.

On succssul clsd-sysm dsign ha is widly usd

is h war-har-basd prcssr (ppularly knwn as

h Applsd racr). Elcric war hars, whhr

purchasd nw r rcvrd rm plumbrs salvag yards,

hav h llwing dsirabl aurs: hy ar salabl,

acry insulad, and cm quippd wih lcric har

lmns, hrmsas, a drain, and svral inl prs a h

p h ank. Rliabl inrmain and plans r buildinga bidisl racr rm a war har can b und in

Rrncs. Th war har racr uss a cnrally

lcad pump r rcirculain h racing bidisl.

Thiseliminatestheneedforamechanicalmixer/stirrer,

simpliying h sysm whil imprving vrall say.

Sald prcssrs mus b quippd wih a mpraur

prssur-rli valv ha is cmpaibl wih h ubing usd

plumb h racr (ms war hars ar sld wih 150-

PSI valvs, and hs shuld b rplacd wih a 30-PSI valv

i using any ply r plasic ubing). A manually prad

vn valv, plumbd h udrs, is als ssnial, asdscribd blw. A sald sysm basd n a mal ank als

allws r h rcvry xcss mhanl rm bidisl

ul and h glycrl by-prduc, which savs mny and

rducs handling and nvirnmnal cmplicains ar

prcssing.

Whn plumbing a racr any dsign, sainlss-sl

r black irn ubing shuld b usd whrvr pssibl, as

hy ar ms cmpaibl wih h chmicals invlvd in

prcssing. Galvanizd ings and any cppr pars will

rduc h xidizain sabiliy (shl li) bidisl,

whil sandard PVC nds brak dwn vr im.

Aluminum shuld als b avidd, as i will vilnly rac

wih ly rm xplsiv hydrgn gas. Many sysms us

brass ball valvs wih n majr ill cs.

Whrvr plasic, ply, r HDPE is usd in bidisl

quipmn, is prximiy ha surcs shuld bcnsidrd. Fr xampl, arly wrks n small-scal

quipmn ppularizd h us cnical-bmd plasic

anks r h main racr vssl. Whil hy d pssss

sm advanags, plasic vssls prsn an incrasd r

and spill risk in h vn an unrsn vrhaing

siuain, srucur r, r hr accidn. In h vn

a r in r nar h prcssing spac, any plasic anks will

likly rupur and rlas hir cnns, pnially adding

ul h r. Haing lmns shuld nvr b insalld

in plasic anks. Ms cnical-bmd plasic anks ar n

100 prcn airigh, and hus will rsul in sm mhanlrlas i usd as a main racr. Ths anks als will n

lra h high mpraurs ndd us h racr as

a mhanl rcvry dvic.

Whil hmmad wdn sands ar cmmnly usd

suppr bidisl quipmn, hs als prsn a wak

link in vrall plan r say. In h vn a r in h

plan, a wdn, il-sakd sand will likly burn, dumping

whavr liquid is in h ank i supprs in h r. An

idal r-sa bidisl plan will us mal anks supprd

n scur mal sands.

Vl, Mhl Fms, d Mk-p Ar

Th main racr and hr prcssing quipmn will

b ladn wih mhanl vaprs a varius ims during

bidisl prducin. Whnvr fuids ar addd r

draind rm a sald racr, mak-up air mus b allwd

fw in r u h racr prvn prssur r

vacuum buildup. Air laving h racr shuld b vnd

hrugh ubing h udrs a a minimum, as i may

cnain xic r fammabl vaprs. Simply running a

mprary fxibl hs rm a valvd pr n h racr

h udrs may b sucin, whil hard-plumbdvning is dsirabl r rgular prcssing. A bs pracic

is vn all mhanl vaprs hrugh a cndnsr r

cllcin, as dscribd in Mhanl Rcvry.

Mhanl ums will als b prsn whn glycrl

is draind rm h racr, and whn raw bidisl

is pumpd rm h racr wash anks, spcially

i hs fuids ar draind whil h. Gas analysis in


16/44

14

Step Heat Pump V1 V2 V3 V4 V5 V6 V7 V8 V9 V10 V11

Oil in

Heat oil ** ***

Inject methoxide

Reaction stage

5% prewash

Drain plumbing

Settle glycerol

Drain glycerol

Distill methanol

Drain biodiesel

Drain site tube

= OPEN or ON

** = Pump should only run periodically*** = Release pressure periodically

taBle 1

FIgure 5

Air Inlet

Methanol VaporsEntering Workspace

Closed and VentedReceiving Container

To Outdoors

Splashing Methanol-laden Fluidsinto Open Containers

is a Dangerous Practice.

Transferring Fluids via Tubingwith a Closed Venting System

is a Safe Practice.

Air Inlet

MethanolVapors

Raw Biodieselor Glycerol

MethanolVapors

Raw Biodieselor Glycerol


17/44

15

n Pnnsylvania bidisl aciliy und mhanl

cncnrains in xcss h lwr xplsin limi (and

prsnal xpsur limi) whn splash-pumping warm

bidisl in an pn wash ank. Rmmbr, i yu can

smll mhanl in h wrkspac, hr is a prblm wih

yur prcss dsign b crrcd. A bs pracic is

ransr all mhanl-ladn fuids via ubing in clsd

vssls, and vn all vssls h udrs, (Figur

5). On innvaiv dsign drains glycrl in a saldcnainr, which has air-vn ubing mprarily plumbd

h main racr, s ha air prssurs bwn h

w vssls can sabiliz wihu mhanl rlas in

h wrkspac r nvirnmn. Pridic vning h

racr h udrs is sill ncssary du hrmal

xpansin and cnracin assciad wih haing and

cling. Hwvr, i his ccurs hrugh a cndnsr,

mhanl rlas is minimizd. Such a umlss dsign

is vry araciv r air-qualiy cnsidrains. Fr urhr

inrmain n umlss prcssing, s Rrncs.

Oprrs Qck Rfrc

Basic prcssing quipmn dvlpd in h hm r

arm shp can bcm cmplicad wih mulipl valvs

and swichs r varius purpss. Evn xprincd

prars can mak misaks, and pning (r ailing

pn) crain valvs during prcssing sags may rsul

in spills r accidnal rlas dangrus chmicals in

h wrkspac. A bs pracic is dvlp a wll-hugh-

u prcss diagram, including sp-by-sp guidlins r

h sa valvs and swichs during dirn sags

prducin (Tabl 1 and Figur 6). This diagram shuldb psd n r nar ul-making quipmn, srv as a

rrnc r all raind prars. In h sampl diagram

blw, ach X rprsns an pn valv, r lcrical

cmpnn urnd n during a givn prcss sp.

Sp-by-Sp Prcss Prcl

In bidisl shps whr mulipl prars us shard

quipmn (c-ps, ducainal aciliis, c.), i is hlpul

prin and ps a sandard prcssing prcl. Such

a dcumn nsurs ha all prsnnl llw prpr say

and ul qualiy prcdurs during ach sp. In addiin,

a bach sp chcklis ha llws a bach ul rm

ank ank n a clipbard is a handy way r mulipl

plan prars cmmunica xacly wha is happning

in ach ank in h shp. Als, a bach rcrd sh ha

dcumns h inpus and prcssing a spcic bach

shuld b mainaind as par h rcrd-kping sysm.

Exampls a bach chcklis and bach rcrd sh can

b und in Appndix B.

Wshg Fl

Wash anks ar cnsidrd ssnial quipmn by ms

prducrs. Thy ar usd nish bidisl by claning

i wih war. Raw bidisl sraigh rm h racr

ypically cnains sap, rsidual caalys, racs glycrl,

and rsidual mhanl i a mhanl rcvry sag

was n prrmd. Whil a w small-scal prducrsrun unwashd ul in hir quipmn, r high qualiy

bidisl ha apprachs h ASTM sandard, washing r

hr sap rmval mhds ar srngly rcmmndd.

An invrd 55-galln clsd-had barrl wih h

bm cu u maks an ardabl wash ank: 25 35

gallns ul can b washd in ach barrl, and drains and

valvs ar asily plumbd in h ings a h bm. A

sand-pip such as h n picurd in Figur 7 is hlpul

r sparaing ul rm war in h wash ank.

Washing ul is achivd by gnly adding war h

bidisl: gnl addiin is impran in rdr avidmulsicain ul and war, spcially in h rs wash

a bach ul. Liklihd mulsin is incrasd

by h prsnc glycrl r sap in h ul, cld

mpraurs, and viln agiain. I is cmmn warm

biodieseland/orwashwaterwhenwashingincoldweather.

Gnl addiin war ul is bs achivd by

ihr mis washing (mis nzzls rain vry n war

FIgure 6

Vent to OutsideV1 V2

V3

V4

V5

V7

V9

Methanol

Recovery

Site Tube

Drain toStorage

Pump

V 8 - MethoxideInlet

Air Injection

V 11 - Drain

V 6 - Oil Inlet


18/44

16

drpls n h surac h ul and h war sls h bm h ank drawing impuriis wih i) r

bubbl washing (air bubbls ar pumpd in clan war

a h bm h wash ank, whr hy ris and pull

h war in h ul, gnly circulaing h war unil i

is saurad wih impuriis.) Bubbl washing is an civ

way rduc h al amuns war usd and was

prducd, sinc i rcirculas war hrugh h ul

svral ims vr.

Prly dsignd washing sysms ar a cmmn caus

spills in bidisl prducin aciliis. In h cas mis

washing, war may b addd h ank vr h curs svral hurs, and h risk ul vrfw in a rgn

wash ank is high. A simpl vrfw prvnin dvic

such as ha picurd abv can b asily buil r a w

dllars. Th us an pn-ppd r a siphn brak

a h p is ssnial prvn accidnal draining h

ank. Ardabl war shu imrs r mr sphisicad

fa swichs ar als advisabl prvn accidnal ul

vrfw; plumbing w gardn war imrs in sris

prvids rdundancy in cas n shuld ail. Thradd

(r sldrd) scur cnncins shuld b usd bwn

h war supply and mising dvic prvn accidnalsparain, lading rapid ank vrfw.

Sild wash war shuld b discardd in a mannr

cnsisn wih suggsins in By-Prduc Handling and

Dispsal. I mhanl was n rcvrd rm h bidisl

ul prir washing, h was war rm h rs wash

will cnain signican mhanl and shuld b handld

wih car.

Prwshg Fl fr Sp Rdc

In rdr rduc h vlum war usd in washing,

and rduc im ha ul spnds in h wash ank, sm

prducrs uiliz a prwash sp whil h ul and glycrl

ar sill in h main racr. War is addd h ul and

glycrl mixur immdialy llwing h iniial mixing.

Typically, warm war qual 5 prcn h riginal

vlum il will b addd racin, hn mixd r

anhr 15 minus r mr. (Fr xampl, in a 50-gallnbach racin, 2.5 gallns war wuld b addd a h

nd h nrmal mixing im). Whn h ul, glycrl,

and war mixur is allwd sl, ms h war will

sl in h glycrl layr, aking sap wih i. Th rsuling

bidisl may b asir wash, rquiring lss war, and

prducing lss was war r dispsal. (Note: Th war

mustb addd whil glycrl is sill in h racr, r ls

mulsicain will rsul rm vigrusly mixing war

and bidisl ghr.) Adding war h racin will

cmplica mhanl rcvry sps, and achiving high-

puriy (dry) mhanl bcms mr a challng. SRrncs r urhr discussin.

Dryg Fl

During h washing prcss, bidisl will bcm cludy

wih suspndd war drpls (smims rrrd as

having an rang-juic-lik apparanc). Washd ul

mus b hrughly drid br us in quipmn

r ransr srag. War in ul can caus srius

damag disl sysm cmpnns, and w ul may als

prm alga grwh in srag anks. Suspndd war

drpls may sl u washd ul vr h curs svral days, dpnding n ambin mpraurs. Passiv

drying may b achivd by allwing washd ul si in

barrls xpsd a brz r svral days, hugh succss

will dpnd n air mpraurs and rlaiv humidiy.

Washd and drid ul shuld b ransparn, sparkly,

and r rm any haz. W ul may appar clariy n

warm days, bu will bcm cludy again as i cls. War

testinginformationcanbefoundinBiodieselQualityTest

Mhds.

In aciv drying, h ul is sparad rm any

sanding war ihr by draining h war r pumpingh ul a spara dry ank. Th ul is hn pumpd

hrugh a circulaing lp ha allws i all hrugh

h air and back in h dry ank, giving h ul inima

cnac wih h air. Incrasd air fw can b achivd wih

a small an dircd in h drying ank. Warming h ul

will spd h drying prcss, spcially n humid days.

FIgure 7

WaterSource

Biodiesel

Wash Water

Misting Head

Biodiesel Drainwith Stand-pipe

WaterDrain

to ApprovedWater Drainor StorageContainer

Bubble Ring

Bracket

Hole for Siphon Break

Air Pump

OverflowPreventionDevice

to ApprovedWater Drainor StorageContainer


19/44

17

Whil us a shwrhad r similar dvic in h drying

ank will incras air cnac (smallr ul drpls), h

pssibiliy r ul amizain prsns a srius r and

halh risk. Succssul drying can b achivd by simply

dircing a sram ul agains h sid a ank and

blwing air acrss h ul. Bubbl drying, in which air

bubbls ar passd hrugh an pn-ppd ul drum

r svral hurs, aks lngr han h prcss dscribd

abv, bu is ypically a clanr, mr nrgy cinmans drying ul. Aciv pump drying prsns anhr

pnial spill pin: all cnncins and muning

drying apparaus mus b scur prvn accidnal

pumping ul n h shp fr.

Du h pn-ppd naur many wash and dry

anks, i is advisabl plac a lr in-lin wih h pump

usd r drying and ransr ul rm h dry ank

ul srag barrls. I h ul hs rm ul srag

barrls is quippd wih a 10-micrn war-blcking disl

ul lr, i will cach any las paricls r war br ul

is pumpd in disl quipmn. A 1-micrn lr may badvisd r nwr, high-prssur injcin disls, as hir

lngviy may b acd by 2- 5-micrn-sizd paricls.

Wrlss Sp Rmvl

Du h inhrn challng prpr wash war

dispsal in rural aras, warlss washing mhds may als

b araciv. Sm small-scal prducrs hav managd

achiv ASTM-qualiy ul wih n washing. This prcss

is ms civ llwing h prwash chniqu

dscribd abv r iniial sap rducin. Th majriy

h cnaminaing sap, rsidual caalys, and glycrlar n slubl in bidisl, bu ar suspndd in bidisl

bcaus hy ar slubl in mhanl. I mhanl is drivn

u h ul (s Mhanl Rcvry), sap and hr

cnaminans will sl u h ul vr a prid

svral days. Sap sparain rm bidisl happns mr

rliably i sdium hydrxid is usd as h racin caalys

(rahr han KOH). Ar h sap is rmvd, h ul can

hn b passd hrugh a sris lrs and pu dircly

in srag wihu war washing. A sap s (dscribd

inBiodieselQualityTestMethods)ishelpfultodetermine

ha h prcss is wrking crrcly.In-xchang rsins, such as Ambrli r Purli

bads, ar usd by sm cmmrcial prducrs r rmval

impuriis insad war washing. Ths bads, which

absrb sap, war, glycrl, and sm mhanl, ar

packd in clumns hrugh which unwashd bidisl

ul is passd. Ar fwing hrugh a sris clumns,

h bidisl is hn lrd and pumpd srag,

rady us. A singl lad bads may prcss numrus

bachs bidisl, dpnding n ul qualiy. Bad

lngviy may b xndd by prcding h bad clumns

wih h mhanl rcvry r sap sparain mhd

dscribd abv. Whil h cs h in-xchang bads

has msly kp his prcss in h ralm largr plans,

small aciliis may nd hm araciv as a way avid

prducing a was war prblm. Fr mr inrmain

n warlss sap rmval and in-xchang bads, sRrncs.

Sm small prducrs rpr adqua succss wih

simply allwing ul sl in barrls r anks r a mnh

r mr llwing glycrl sparain, which als prms

sap sling via graviy. In his cas, ul shuld b drawn

h p h barrl, laving h sapy layr bhind.

Ful cland by sling aln shuld b cnsidrd

suspc qualiy, and mnird carully r any quipmn

prblms.

Storage Issues

Ol Cllc

Br cllcing il rm any rsauran, b sur ask

prmissin rm h managmn. Oil ha has bn placd

in a rndring cmpany barrl chnically blngs ha

cmpany, and shuld n b akn dspi prmissin

rm h rsauran. T avid lgal rubl, prvid yur

wn barrl, r ask h rsauran sav h usd il in h

plasic jugs ha ar mpid ach im hy add rsh il

h ryrs. Barrls shuld b clarly labld usd cking

il. I yu nr in a gras cllcin agrmn wih a

rsauran, i is ssnial rliably cllc il n a schdulha wrks r h rsauran.

Small-scal bidisl prducin is asis wih high-

qualiy il ha is r rm war and xcssiv d

paricls, ds n smll rancid, and is lw in acid du

rgular ryr changs. Oudr il srag a rsaurans

shuld b scurly cvrd prvn war and vrmin

rm nring cnainrs.

Th PADEP rgulas h ransprain usd

cking il. Each vhicl usd in cllcin mus bar

a labl (dcal r magnic sign) rading MUNICIPAL

WASTE r RESIDUAL WASTE (i i is rm a d-prcssing plan) plus h nam and addrss h

vhicl wnr. All lrs n h sign ar rquird b six

inchs in high, r radabl rm a rasnabl disanc.

In addiin, h cllcin vhicl mus carry a lg ha

indicas whr il is cllcd and h numbr gallns

pr pickup. A r xinguishr mus als b carrid in h

cllcin vhicl. Th sam vhicl cann b usd


20/44

18

ranspr d r animal d.

Spill-r cllcin and ransprain will nsur a

lasing gd rlainship wih rsaurans and rgulary

agncis. Kping a buck an absrbn il dry

marial and a spill ki in h cllcin vhicl is advisd

in cas spills. Scndary cnainmn in h cllcin

vhicl is dsirabl, as is scuring any bucks r barrls

prvn spills during ransprain. Tak car n

vrlad h rad hauling capaciy yur vhicl wihhavy il drums r s. Whil a vhicl may physically

carry mr wigh han i is rad r, braking abiliy may b

incrasd whn vrladd, prsning an accidn hazard.

Oil can b srd r six mnhs a yar br

prcssing, idally srd in a cnainr wih minimal air

spac. Larg havy duy plasic s (300- 350-galln

cubs) quippd wih drains a h bm mak handy

il srag cnainrs. (Ths mus b wll-supprd; 300

gallns il wighs abu 2,100 punds wihu adding

h wigh h cnainr.) Oil can b rugh-lrd by

puring i hrugh a scrn whn ransrring rm hcllcin vhicl srag. War and d paricls will

naurally all h bm h cnainr vr im, and

can b pridically draind. Oil r prcssing shuld b

drawn h p h cnainr avid any wary

layr blw.

Chmcl Srg

All hazardus chmicals (and any cnaminad prcssing

gar) shuld b kp in lckd srag cnainrs whn

n in us. A bs pracic is us an apprvd mal

r cabin r srag fammabl liquids. Havy duy5-galln plasic carbys ar handy r mhanl srag

and ransprain. Handling mhanl is rducd i

using carbys ha can b plumbd dircly h bidisl

racr r chmical addiin h dsck il. Chmical

srag cnainrs shuld b clarly idnid wih say

labls advis r r say prsnnl and hrs in cas

an mrgncy.

Lblg Srd Flds

A bs pracic is labl all srag cnainrs,

rm bucks glycrl by-prduc larg anks

usd cking il. I is vry asy ls rack which

unidnid brwn fuid may b in an unmarkd

cnainr. Labling prvns accidnal misus fuids,

and will hlp mrgncy-srvic prsnnl knw wha hy

ar daling wih in cas an accidn. Papr ags wih

srings r wirs sld a c-supply srs ar asily axd

jug and buck handls. (Pncil r prmann markr

is h ms rliabl r marking ags in ily cndiins).

Cnainr labls shuld indica h yp fuid, any

disinguishing characrisics, and h da h fuid was

prducd r srd. Daing was cnainrs is paricularly

impran b sur ha srag ds n xcd h n-

yar limi rgulad by h PADEP. Mhanl cnainrs

shuld b labld fammabl and ly r KOH cnainrs

shuld b labld crrsiv. Sickrs r labling may als

b availabl rm chmical supplirs.

Spills

Spills hazardus marials r il ar asis clan up i

hy ar kp pavd r cncr aras. I h spill ccurs

n hs aras, gra r shuld b mad kp i n

hs suracs and n allw i migra sil, in srm

swrs r manhls, r hr surac war. I a spill nrs

surac war r h srm war sysm, i bcms a high-

impac spill and mus b rprd 911 r mrgncyclanup rspns. Typically his will invlv h cuny-

dsignad Hazma am.

Fr smallr spills and rlass (hs ha can

b saly handld by h bidisl prducr and d n

nr srm swrs, manhls, r hr surac war), h

llwing prcdurs shuld b usd:

Identifytheproblem.

Stopthesourceofthespill/release.

Containthespill/releasebyusingabsorbentsocks,

orpreventthespill/releasefrommigratingtootheraras such as sil, drains, r surac war by using h

absrbn scks r cnsrucing a dik.

Recoverthespilled/releasedmaterialandaffectedsoil

r gravl by cvring i wih absrbn marials (pads,

pillws, r ls absrbn marial). Ohr marials

can b usd as ndd including shp rags, sawdus,

etc.Allfreeproductmustbeabsorbed.Ifthespill/

FIgure 8

Glycerol

Batch # SPO7-12

NAOH Lye

Contains Water

and Methanol

6/14/07


21/44

19

rlas is sil r gravl, xcava all marial ha

is acd. Us bh visual bsrvains and drs

drmin h xn marial b xcavad.

Properlydisposeoftheusedabsorbentmaterialsand

excavatedsoil/gravel.Usedcookingoilspillsandsmall

wip-ups hazardus marials such as mhanl may

b dispsd as municipal was. Spills mhanl,

r hr chmicals ha saura h absrbn marial,

shuld b dispsd as hazardus was. ReportthespilltothePADEPifitoccursoutdoorsor

nrs any srm-war drains, manhls, r surac

war. Prvid inrmain n h lcain h spill,

h marial spilld and is vlum, and h acd

mdia (war, sil, c.).

I is hlpul hav a spill ki n hand asily dal

wih spills. Th ki shuld cnain sm ls absrbn

marial such as kiy lir, as wll as pads ha ar dsignd

absrb ils and hr chmicals. Scndary cnainmn

arund il and ul srag aras is a highly rcmmnddmanagmn pracic in anicipain spills. A shr

paind r sald cncr curb r dik arund il srag

anks shuld b sizd accmmda pnially spilld

il, r a surdy wdn nclsur lind wih pnd linr

r havy-duy plasic may suc r a mprary sluin.

Fr small-scal prducrs, plasic childrns pls ar an

ardabl pin r spill prvnin arund barrls.

Cnainmn any kind shuld b sizd accmmda

a las 110 prcn h vlum h singl largs

cnainr in h cnainmn ara. Using h gur

1 galln quals 7.48 cubic , yu can calcula happrpria siz yur cnainmn ara r yur largs

ank. I is pssibl mak h nir shp fr in

n larg cnainmn ara using a shr wall arund a

cncr fr.

By-Product Handling and Disposal

Glycrl

Th answr h qusin Wha d yu d wih h

glycrl and wash war? is a mving arg. Ruls and

rcmmndains rgarding lgal and nvirnmnally

rspnsibl by-prduc dispsal ar likly chang vr

im as rsarch is carrid u, and h rgulary agncis

cnsidr h applicains h law. Wha llws is h

auhrs bs pssibl synpsis h availabl inrmain

a h im publicain. Bidisl prducrs ar

advisd say in cnac wih hir lcal PADEP c

and bidisl prducin nwrks r h las n his

vlving issu. Suc i say ha rspnsibl glycrl

dispsal is a majr sicking pin r small-scal prducrs.

Th ppruniy r innvars ak advanag his

was prduc r a y--b-drmind bncial us is

prund.

Bidisl prducin will rsul in signican quaniis

rsidual glycrl by-prduc. Fr ach galln bidisl

produced,approximately1/5gallonofglycerolwillresult.

Rning crud bidisl glycrl in pur, markabl

glycrin is chnlgically dicul, xpnsiv, and is n

cnsidrd pracical n a small-scal. Nw prducrs shuldgiv ampl cnsidrain hw hy will disps hir

by-prduc br bginning a bidisl aciliy. Srag

glycrl by-prduc shuld b dn in accrdanc wih

applicabl scins Til 25 Pa. Cd Chaprs 285 and

299, as i prsns a halh and r risk. Glycrl srd

in plasic ryr il jugs will lak vr im. Srag cann

xcd a n-yar prid, as his is cnsidrd n-si

dispsal. S Rrncs r a link h Pnnsylvania

Cd, which prvids h rgulains rgarding srag

rsidual and municipal was marials.

Crud glycrl by-prduc is cnaminad wihmhanl (apprximaly 25 prcn by vlum) and as

such may b cnsidrd hazardus was. Cnrary

ppular bli, mhanl will n vapra rm srd

glycrl a ambin mpraurs sucinly cnsidr

h glycrl uncnaminad. Raw, mhanl-ladn glycrl

by-prduc shuld b handld as i i wr mhanl. This

includs waring glvs and gggls and aviding any

cncnrad vaprs.

Land applicain glycrl ha is cnaminad wih

mhanl may rsul in mhanl laching in grund

war, laving bidisl prducrs liabl r any damags drinking war surcs. Land applicain cnaminad

glycrl will crainly rsul in air missins mhanl.

Mhanl is a lisd hazardus air plluan by h EPA

and PADEP du is impac n human halh and hr

rganisms.

A bs pracic is rcvr h mhanl rm h

glycrl by-prduc via disillain, prir dispsal r

urhr us. Mhanl rcvry rducs nvirnmnal

plluin and allws prducrs rus mhanl,

hrby rducing css and imprving nrgy balanc.

Mhanl rcvry has sm inhrn say cncrns, andshuld nly b carrid u by advancd prducrs wh

ully undrsand h say issus invlvd wih handling

mhanl and h liquids. Hwvr, h auhrs his

bkl srngly rcmmnd ha all bidisl prducrs

incrpra mhanl rcvry sysms in hir lng-rm

plan dsigns. Nw prducrs may cnsidr sckpiling a

mds amun glycrl unil hy ar rady advanc


22/44

20

mhanl rcvry. A criical faw h small-scal

bidisl cmmuniy is ha h hazards mhanl-

cnaminad glycrl hav bn casually brushd asid,

and mhanl rcvry has bn cnsidrd an pin

rahr han a rquirmn r a maur prducin aciliy.

Fr mr inrmain n mhanl rcvry, s Mhanl

Rcvry and Rrncs.

Crud glycrl has a high pH du a rsidual NaOH

r KOH caalys rm h bidisl racin. I acid is addd h by-prduc nuraliz h pH, his may allw h

rcvry sm addiinal r ay acids r prcssing

in bidisl. Sals such as sdium chlrid r passium

phspha (dpnding n acid and caalys chics) will

rsul rm acidulain. This may b cnsidrd was

prcssing and wuld rquir a prmi rm PA DEP.

Glycerol Contaminated with Methanol

Currnly n asily aaind pins r dispsal glycrl

wih mhanl ar allwd by h PADEP. Sm pins

ar undr invsigain and may b allwd as mr daabcm availabl. In hr sas, us as a dsck r n-

arm cmpsing r anarbic (bigas) digsin may b

allwd, as wll as incrprain in landlls. Plas chck

wih rgulars in yur sa r h las inrmain and

prmiing rquirmns.

AnaerobicDigestion:Crudeby-producthasbeenadded

anarbic bigas (mhan) digsrs wih succss

in svral lcains, including arm-scal manur

digsrs and municipal was war ramn plans.

In cnrlld anarbic digsin, micrbs dcmps

animalmanuresand/orhumanwaste,producingmhan gas ha may b usd r pwr gnrain.

Ths micrbs ar capabl braking dwn

mhanl and glycrl in mr bnign cmpunds.

Th addiin bidisl glycrl by-prduc may

acually bs bigas prducin. Th glycrl by-

prduc ypically has a high pH and a high carbn

nirgn rai, which may als mak i araciv as a

digsr addiiv. Dilu addiins small amuns

glycrl by-prduc shuld b sd whil carully

mniring h rspns h digsr. Fr a lising

arm-basd manur digsrs in yur ara, cnacyur cuny Pnn Sa Cpraiv Exnsin c.

This us is n currnly apprvd by h PADEP. Plas

cnac yur lcal c rqus a prmi shuld yu

dsir pursu his urhr.

IndustrialCombustion:Glycerolby-productmaybe

allwd r us as a blndd ul in indusrial burnrs

and bilrs, such as cmn and lim kilns i i is

classid as a c-prduc. Tsing nsur ha h

fash pin xcds 140 dgrs Fahrnhi (60 dgrs

Clsius) mus b dn n h was marial nsur

i is n classid as a hazardus was, which wuld

prvn is us in a ul-using sysm n prmid

r hazardus was incinrain. High-mpraur

burning is impraiv avid h rmain highly

xic acrlin, which rsuls rm burning glycrl a

mpraurs lss han 536 dgrs Fahrnhi (280dgrs Clsius). Acrlin, a suspcd carcingn, is

dangrus living hings a cncnrains as lw as

w pars pr millin. Fr his rasn (and cnsidring

h r and halh hazards handling mhanl-

cnaminad by-prduc in h hm), hm-scal

burning glycrl is n rcmmndd. Th Air

QualitysectionofthePADEPneedstobeapprisedof

any ul-burning siuains wih his marial.

Glycerol After Methanol Recovery

IndustrialCombustionasdescribedabove.TheAirQualitysectionofthePADEPneedstobeapprised

any ul-burning siuains wih his marial. Th

Was Managmn scin shuld als b cnsuld

r prmissin dsigna glycrl as a c-prduc r

us as ul.

Composting.Aftermethanolremoval,glycerol

can b saly cmpsd wih rducd cncrn r

nvirnmnal cnaminain. Glycrl by-prduc

is a high-carbn, high-pH, w dsck, and shuld

b cmbind wih a bulking agn (sraw, hay, lavs)

and sm nirgnus marials (manurs r rshgrn yard wass) r prpr cmpsing. Glycrl

shuld b addd cmps pils in dilu amuns

prvn w saurain lading anarbic cndiins.

Frqun urning pils will prm spdy arbic

dcmpsiin and an vn disribuin glycrl in

h mix. Glycrl cmps pils shuld b cnsrucd

ar away rm any war surc prvn run

cnaminain. Cvring pils wih cmmrcially

availabl cmps abrics will prvn war saurain

and rduc run pnial. Sils whr cmps is

applid shuld b sd rgularly r any sal builduprm rsidual bidisl caalys in h glycrl by-

prduc. Th PADEP rquirs a prmi r his mhd

dispsal, s cnsul yur lcal c. Unil urhr

rsarch in h acin crud bidisl glycrl in

h cmps pil can b cnducd, h auhrs d n

rcmmnd adding glycrl cmps pils usd

riliz d gardns.


23/44

21

Soap.Glycerolcanbeprocessedintoacrudehandor

bdy sap using simpl rcips (s Rrncs). I is

impraiv ha all mhanl has bn rmvd rm

h glycrl br making sap. T b crain, glycrl

shuld b had slwly 212 dgrs Fahrnhi (100

dgrs Clsius), which is h biling pin war. I

bubbling ccurs in h glycrl p br 212 dgrs

Fahrnhi (100 dgrs Clsius) is rachd, hn sm

mhanl is sill prsn. Haing shuld cninu uniln bubbling ccurs a mpraurs blw 212 dgrs

Fahrnhi. Whn making sap, us nly sainlss sl,

glass, r cramic ps (n aluminum). Haing shuld

ccur udrs vr an lcric burnr prvn any

cncnrain ums r igniin sray mhanl

vaprs.

Degreaser.Asimplebuteffectiveenginedegreaseror

oorcleanercanbemadebymakinga50/50blendof

war and glycrl ar mhanl rmval. Individual

bidisl prducrs rpr a srng dmand r

glycrl dgrasr in sm lcains.

DustSuppressant.Aftermethanolrecoveryiscomplete,

glycrl by-prduc has bn blndd wih war and

sprayd n rads and dir racks as a dus supprssan.

Glycrl ass sw animals and may draw wildli

rads, s cauin is advisd. Avid spraying nar

any warways prvn cnaminain. Any land

applicain was marial mus hav prmissin

rm yur Rginal PADEP Oc and h wnship r

sa i hy hav jurisdicin h rad.

AnimalFeedAdditive.Earlyexperimentsshow

sm succss wih adding glycrl animal d

ar mhanl rcvry. Glycrl is a sw, high-

carbhydra nrgy surc ha may b addd grain

ds in dilu quaniis. Furhr rsarch is ndd

drmin prpr blnding ras and h pssibl

cs passium r sdium sals and high pH h

by-prduc. Fr mr inrmain, s Rrncs.

Wsh Wr

Wash war was rm bidisl prcssing prsns a

signican dispsal and handling challng in rural aras.

Ths wh hav accss a public saniary swr may b

prmid disps wash war by hir lcal war

ramn auhriy. Cnac yur war ramn auhriy

r prmissin br dispsing wash war h

saniary sysm.

Wash war may b cnaminad wih any h

llwing: mhanl (rs wash, i mhanl rcvry sp

was n carrid u n ul), sap, xcss caalys, glycrl,

vgabl ils, r ay acids, and bidisl. Wash war

will ypically hav a high, alkalin pH. Th pH h war

shuld b sd prir dispsal in a saniary swr. Lcal

rgulains vary, bu any liquid wih a pH highr han

9.5 r 10 is cncrn du is crrsiv naur. Th

alkaliniy wash war may b nuralizd in bachs using

vingar r dilu muriaic acid. Hwvr, prramn

r nuralizing a was prir dispsal is rgulad undr

PADEP Prmi-By-Rul rgulains r nuralizain,pnding s rsuls r was drminain as hazardus

r rsidual. Each cas will b handld sparaly by h

PADEP, dpnding n h s rsuls h was and h

nds and yp ramn plan invlvd. A h vry

las, h ramn aciliy prar and lcal PADEP War

Qualitysectionshouldbeconsultedpriortoseweringwash

war.

Mhanl-ladn wash war will hav a high bilgical

xygn dmand (BOD), which is cncrn war

ramn plans. Sm ramn plans ar vry wary

fammabl liquids in swr war. Lcal lrancs rmhanl in swr war may vary.

Vgabl il r bidisl in wash war can als

cnund war ramn and swr sysmsmany

plans hav vry lw lrancs r as, ils, and gras. A

bs pracic is pass wash war (and war rm sinks

whr bidisl lab war is cland) hrugh a gras rap.

Cmmrcially availabl gras raps will prvn xcssiv

il cnaminain h was war sram. An civ

gras rap can als b mad rm plumbing pars and a

larg plasic (Figur 9).

FIgure 9

12

22 1/2

Grease Trap Flow Rate: 4GPM~ 8lb. Grease Capacity


24/44

22

N ha h ul pip xis h rap slighly lwr

han h inl pip, and ha h ul pip draws war

rm nar h bm h ub. Bafs may b addd

alng h bm ncurag as ris. A small vn

hl shuld b drilld in h uppr prin h ul

pip prvn siphning. Fas will cllc a h surac

h liquid in h rap, and mus b skimmd h p

rm im im.

I wash war is allwd sl r svral days, msil in h war will ris h surac, whr i can b

skimmd and rurnd h wash ank. Sm usrs

als add Epsm sals (magnsium sula) whil araing

wash war, which will caus saps prcipia u

sluin.

Rspnsibl dispsal wash war is a cmbinain

h abv chniqus (mhanl rcvry, nuralizain,

il sparain, and sap rmval.) Sm small-scal

prducrs rpr succss wih bilgical lrain wash

war in a sris arad anks srving as cnsrucd

wlands, in which plans ar grwn accumula anycnaminans. Cmpsing r dilu ld applicain may

b allwd as a nrmal arming pracic, prvidd ha h

armr gnras h was and is making h bidisl r

nncmmrcial us n h arm. Havy land applicain

cncnrad, raw wash war will ngaivly ac sil

rganisms du h ils and high pH. Cmps pils and

lds shuld b mnird r any unusual sal r nurin

buildup. Ths prcsss lnd hmslvs a pnial

Prmi-by-Rul rm h PADEP; s cnac yur lcal c.

Wash war shuld b prvnd rm nring

warways, srm swrs, grund war, and hr warrun channls a all css. Bidisl prducrs wh

cnamina warways wih wash war r hr wass may

b hld accunabl by law.

Givn h many challngs prpr wash war

dispsal n arms, many prducrs may nd warlss sap

rmval as dscribd in Prcss Say and Handling Issus

b araciv.

Bd Vgbl Ol

Small prducrs wrking wih usd cking il will

inviably ncunr sm marial ha is unusabl rprducin bidisl. Tank bms, il ha is xcssivly

ladn wih d paricls, rancid il wih a ul dr,

andoil/wateremulsionsareexamplesofwhatmaybe

cnsidrd bad il. Th llwing ar dispsal pins

naivly apprvd by h PADEP. A prmi may b

rquird r sm pins. Plas cnsul yur lcal PADEP

c nsur cmplianc wih h las rgulains.

Any land applicain ha rsuls in ul drs acing

nighbring prpris is likly b prhibid.

Applicationtogravel/dirtfarmroadsfordust

supprssin and paving. Many armrs rpr

civ cnrl dus using dilu addiins

vgabl il unimprvd rads. Car mus b akn

avid applicain whr run culd nr any

srm swr, sram, r hr war surc. Vgabl

il may draw ps r wildli rads. Kp accurarcrds h da, im, lcain, and quaniy

vgabl il applid rads. Cnsul yur lcal PA

DEP c prir applicain.

Compost.Vegetableoilwillcompostifsmallamounts

ar addd absrbn marial (sraw, hay, lavs,

wd, c.) in a larg cmps pil. Oils nd slw

h cmpsing prcss, bu may als hlp i up

slubl nirgn. Kp accura rcrds h da,

im, lcain, and quaniy vgabl il applid

cmps pils.

Burninginbonres/woodfurnaces.Thisusemay

rquir a prmi rm h air qualiy scin h

PADEP.

Mixwithabsorbentmaterialandlandll.Consult

wih yur landll adminisrar r rash haulr br

dispsing larg quaniis il in his mannr.

Oil-sakd sawdus prsns a dangrus spnanus

cmbusin r hazard and mus n b allwd

lingr in r arund buildings. Oily sawdus shuld

b wd dwn wih war and packd in sald

cnainrs avid saring a dumpsr r.Tracking Emissions: Where Does the Methanol Go?

Mhanl is an air plluan cncrn r h PADEP

and h Unid Sas EPA du is pnially harmul

impac n humans and hr rganisms. In Pnnsylvania,

aciliis ha mi in h air n n (2,000 lbs) r mr

mhanl pr yar ar rquird bain a prmi rm

h PADEP. Faciliis ha mi lss han n n pr yar

ar currnly xmp rm prmiing. As a bs pracic,

small prducrs can mnir and rcrd hir mhanl

missins nsur ha hy all wll blw h xmp

lvls. This scin discusss sm acrs invlvd in

racking mhanl missins.

A galln mhanl wighs abu 6.6 punds a

rm mpraur. On n mhanl is hrr

qual apprximaly 303 gallns. A aciliys mhanl

missins will dpnd n annual prducin vlum and

prcssing mhds: Ds h sysm includ mhanl

rcvry? Hw much mhanl is usd in h racin? Is


25/44

23

i a clsd sysm? Tabl 2, abv, can b usd as a rugh

guid pnial missins. Frm h char, w can s

ha h annual hrshld prducin lvl blw which n

air qualiy prmi is currnly rquird is 3,366 gallns raciliis using 22 prcn mhanl, and 2,525 gallns r

aciliis using 25 prcn mhanl. Hwvr, prducrs

shuld n cnsidr his a pass mi mhanl in

h air. Rspnsibl individuals will wrk minimiz hir

missins his air plluan hrugh mhanl rcvry

and gd prcss dsign. Opn-ppd racrs will mi

signicanly mr mhanl han a clsd sysm.

Bdsl Chmsry

Th mhanl rquird cnvr vgabl il

(riglycrids) in mhyl srs (bidisl) and glycrl in

h ranssricain racin is apprximaly 13 prcn

h saring il vlum. Hwvr, ypical bas-caalyzd

bach racins us xcss mhanl in rdr achiv

ull cnvrsin h il in ul. Th bidisl racin is

rvrsibl. Wihu a surplus

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