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Conditioning used frying oil for conversion to biodiesel
Shane Bird, Marie Stark, Kate Burlingame,
Chuck Weatherspoon, John Neal
French Fry FuelSponsored by J.R. Simplot, Co.
Design Review Outline
Background Accomplishments Problem Definition Remove Particulate Matter Reduction of Water Content from Oil Reduction of FFA Content from Oil Integrated Solution Concepts Project Challenges Budget/Timeline Discussion Questions
Background
The J.R. Simplot Company generates 2 million pounds of waste oil each year.
Simplot would like to condition the oil and convert it to biodiesel, which would then be returned to Simplot to offset the diesel used in the transportation fleet.
Accomplishments
The waste oil generated in production lines forms two waste streams.
Team French Fry Fuel has performed numerous tests on the mainstream oil. We determined that it is suitable for conversion to biodiesel.
Problem Statement
The secondary waste stream generated, DAF (Dissolved Air Floatation) oil, is an economic drain on Simplot.
Our goal is to pretreat both elements of DAF oil, MOP (oil from plant clean-up) and WESP (wet electrostatic precipitator), before sending them to a biodiesel manufacturer.
In order to condition the oil, the team will design a system to remove free fatty acids, water, particulates, and other carbon impurities from the used oil to a specification defined by the biodiesel manufacturer.
<4% FFA <.1% Water by weight <50-100 micron particulate size
Integrated Solution
Self Cleaning Paper Filters
Biodiesel Conversion for FFA < 4%
Heat
FilterWater
RemovalEsterification for
FFA > 4%
Bag Filter
Falling FilmEvaporator
FlashEvaporator BD20
BeadsSulfuric
Acid
Test FFA Level
Test FFA Level & Water Content
Particulate Removal: Bag Filter
Advantages: Easy to clean. Filters large amounts
of particulates. Low start-up cost.
Disadvantages: Large particulate may
push through filter bags.
Manual maintenance. Felt Filter Bags Easy Access Filter-Bag
Housings Stainless Steel
http://www.mcmaster.com/
Particulate Removal: Self-Cleaning Paper Filter
http://www.heatandcontrol.com/product.asp?pid=46
Advantages: Self cleaning. Filters large amounts
of particulates. Low maintenance.
Disadvantage: High Start-up cost.
Continuous Paper Filter
FFA Reduction: Acid Esterification Using Sulfuric Acid
1. Sulfuric acid (catalyst) is dissolved in methanol, then added to the oil
2. While the reaction takes place continuous dewatering must also occur
Advantages: Can be batch or continuous Higher removal of FFA Make more fuel out of high
FFA feedstock
Disadvantages: Must remove water
continuously for high yields Potential hazardous chemical,
methanol utilized Increased chemical cost
FFA Reduction: BD20
This emerging technology uses the same principles as acid esterification.
Advantages: Treats oils with FFA ranging from 0.5 to 100% Fast reaction time High conversion efficiency Can treat oils with low levels of water Fewer toxic chemicals
Disadvantages Availability issues Unknown cost
Water Reduction: Falling Film Evaporator
Falling film evaporators work by allowing a film of the liquid to flow down the tubes of the heat exchanger.
Advantages: Will remove high water
content from fluids Works with low
temperature differences. Disadvantages:
Complicated design Requires higher heat
A: ProductB: VaporC: ConcentrateD: Heating SteamE: Condensate
1: Head2: Calandria3: Calandria, Lower part4: Mixing Channel
5: Vapor Separator
www.niroinc.com/evaporators_crystallizers/falling_film_evaporators.asp
Flash Evaporation(Water Removal)
Flash evaporation is the vaporization of a saturated liquid (in this case oil) as it undergoes a pressure reduction through a small orifice or throttling device.
The oil is heated and then sent via a pump to the feed inlet where it goes through a reduction in pressure. The applied heat and reduced pressure converts the water in the oil to a vapor.
Note: If the oil has greater than 5% water in it then multiple evaporators may be needed to remove that water to an acceptable level.
http://en.wikipedia.org/wiki/Flash_evaporation
Recommended Treatment Process
Heated
Agitated
Tank
Filter SystemEvaporator
Esterification
Methanol
Recovery
Q
Q
Water
Water
P P
P
P
P
To Blue Sky DAF Oil
Particles
(1)(2)
(3)
(1) Sample taken for Water content and FFA testing
(2) Send to Blue Sky if FFA ≤ 4% FFA
(3) Test for Water and FFA content
Cost for Full Scale Design
Process Unit Cost/Unit Est. Cost
Sulfuric Acid 5 190mL Bottles
$32.00
BD-20
Bag Filter Ea. $1200 $1500
Self Cleaning Ea. $100,000
Flash Evaporator Ea. $50,000
Falling Film Ea. $60,000
Design Challenges
Further lab analysis of the WESP and MOP oils will allow us to determine a treatment plan.
Hazardous chemicals near food processing plant.
Effective cost analysis. Bench-top model.
Timeline
Snapshot Day ……………….Nov. 30 2007
Semester End Report Due…Dec. 11 2007 Winter Break…………………Dec. 14 2007 Spring Semester Begins…….Jan. 9 2007 2nd Design Review………….Feb. ?? 2008 Final Report Due…………….May ?? 2008 Engineering Expo……………April 25 2008
Questions?
Ideas, Comments, or Suggestions