Development of a biodiesel production plant

Panel Presentation: Energy Author: Prasad Ramesh Patil Institution: University of Liverpool

Development of a biodiesel production plant

Abstract

Fuels are inevitable for industrial development and growth of any country. The lifebeen terrifying. Biodiesel, a renewable source of energy seems to be an ideal solution for global energy demandsincluding India as well. Amongst different biofuels pathways available, biodiesel from agriculture defeedstock appears to be the feasible ready to market. The objective of the present work is to make a detailed analysis ofa biodiesel production plant design characteristics, considering that the raw materials will also be locally producFurthermore, the feasibility of such a plant is evaluated and useful conclusions are drawn in respect to the unit productioncost and various other technical and economical parameters.

Keywords: Biodiesel, Transesterification Catalyst Alcohol ProductiCost

1. Introduction

Interest in renewable fuels has increased substantially in recent years. Much of this interest is attributable due to theupward trend of traditional fuels cost, environmentalforeign energy. This has lead to increase in demand of the alternative fueldiesel engines that is gaining attention all over the world. Itrenewable fuels currently available and it is also nonengines without requiring extensive engine modifications.

What is biodiesel?

Biodiesel is defined as the mono-alkyl esters of fatty acids derived from vegetable oils or animal fats. In simple terms,biodiesel is the product is available when a vegetable oil or animal fat is chemically reacted with an alcohol to produce anew compound that is known as a fatty acid alkyl ester. A catalyst such as sodium or potassium hydroxide is required.Byproduct produced is Glycerol.

The approximate proportions of the reaction are:

100 kg of oil + 10 kg of methanol

l reaction of Biodiesel process. Source:

EWB-UK National Research & Education Conference 2011

Development of a biodiesel production plant Prasad Ramesh Patil

Supervisor: Dr Tim Short

University of Liverpool

Fuels are inevitable for industrial development and growth of any country. The life span of fossil fuel resources has alwaysbeen terrifying. Biodiesel, a renewable source of energy seems to be an ideal solution for global energy demandsincluding India as well. Amongst different biofuels pathways available, biodiesel from agriculture defeedstock appears to be the feasible ready to market. The objective of the present work is to make a detailed analysis ofa biodiesel production plant design characteristics, considering that the raw materials will also be locally producFurthermore, the feasibility of such a plant is evaluated and useful conclusions are drawn in respect to the unit productioncost and various other technical and economical parameters.

Biodiesel, Transesterification Catalyst Alcohol Production units, Biodiesel plant Design and feasibility Analysis,

Interest in renewable fuels has increased substantially in recent years. Much of this interest is attributable due to theupward trend of traditional fuels cost, environmental concerns associated with fossil fuels, and increasing dependence onforeign energy. This has lead to increase in demand of the alternative fuel Biodiesel. Biodiesel is an alternative fuel fordiesel engines that is gaining attention all over the world. Its primary advantages deal with it being one of the mostrenewable fuels currently available and it is also non-toxic and biodegradable. It can also be used directly in most dieselengines without requiring extensive engine modifications.

alkyl esters of fatty acids derived from vegetable oils or animal fats. In simple terms,biodiesel is the product is available when a vegetable oil or animal fat is chemically reacted with an alcohol to produce a

ound that is known as a fatty acid alkyl ester. A catalyst such as sodium or potassium hydroxide is required.

The approximate proportions of the reaction are:

100 kg of oil + 10 kg of methanol → 100 kg of biodiesel + 10 kg of glycerol

ChemiFigure:-1 Chemicacal reaction of Biodiesel process. Source: s.

UK National Research & Education Conference 2011

‘Our Global Future’

4th March 2011

19

span of fossil fuel resources has always been terrifying. Biodiesel, a renewable source of energy seems to be an ideal solution for global energy demands including India as well. Amongst different biofuels pathways available, biodiesel from agriculture derived and low cost feedstock appears to be the feasible ready to market. The objective of the present work is to make a detailed analysis of a biodiesel production plant design characteristics, considering that the raw materials will also be locally produced. Furthermore, the feasibility of such a plant is evaluated and useful conclusions are drawn in respect to the unit production

on units, Biodiesel plant Design and feasibility Analysis,

Interest in renewable fuels has increased substantially in recent years. Much of this interest is attributable due to the concerns associated with fossil fuels, and increasing dependence on

. Biodiesel is an alternative fuel for s primary advantages deal with it being one of the most

toxic and biodegradable. It can also be used directly in most diesel

alkyl esters of fatty acids derived from vegetable oils or animal fats. In simple terms, biodiesel is the product is available when a vegetable oil or animal fat is chemically reacted with an alcohol to produce a

ound that is known as a fatty acid alkyl ester. A catalyst such as sodium or potassium hydroxide is required.

of glycerol

BiofuelsysteBiofuelsystemms. [1]

Developpment of a biodiesel production plant by Prasad Ramesh Patil is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License.


2. Production Process

There are three methods of biodiesel production. This classification is based on the type of catalyst used

1. Base-catalyzed transesterification of the oil with methanol2. Acid-catalyzed esterification of the oil with 3. Supercritical methanol process.

Most of the biodiesel produced today is done with the base catalyzed reaction or with Supercritical Methanol in comparison with acid catalyzed esterfication

Base-catalyzed transesterification of the oil with metha

The block flow diagram shown below of the process of a base

The base catalyzed production of biodiesel generally occurs using the following steps

Mixing of alcohol and catalyst: The catalyst is typically sodium hydroxide (caustic soda) or potassium hydroxide (potash). It is dissolved in the alcohol using a standard agitator or mixer.

Reaction: The alcohol/catalyst mix is then charged into a closed reaction vesfrom here on is totally closed to the atmosphere to prevent the loss of alcohol. The reaction mix is kept just above the boiling point of the alcohol (around 160 °F) to speed up the reaction and the reaction taketime varies from 1 to 8 hours, and some systems recommend the reaction take place at room temperature. Excess alcohol is normally used to ensure total conversion of the fat or oil to its esters. Care must be taken to monitor tamount of water and free fatty acids in the incoming oil or fat. If the free fatty acid level or water level is too high it mcause problems with soap formation and the separation of the glycerin by

Separation: Once the reaction is complete, two major products exist: Glycerin and biodiesel. Each has a substantial amount of the excess methanol that was used in the reaction. The reacted mixture is sometimes neutralized at this step if needed. The glycerin phase is much denser than bio

simply drawn off the bottom of the settling vessel. In some cases, a centrifuge is used to separate the two materials faster.

Alcohol Removal: Once the glycerin and biodiesel phases have been removed with a flash evaporation process or by distillation. In others systems, the alcohol is removed and the mixture neutralized before the glycerin and esters have been separated. In either case, the alcohoequipment and is re-used. Care must be taken to ensure no water accumulates in the recovered alcohol stream.

Glycerin Neutralization: The glycerin byand sent to storage as crude glycerin. In some cases the salt formed during this phase is recovered for use as fertilizer. Inmost cases the salt is left in the glycerin. Water and alcohol are removed to produce 80to be sold as crude glycerin. In more sophisticated operations, the glycerin is distilled to 99% or higher purity and sold into the cosmetic and pharmaceutical markets.

Methyl Ester Wash: Once separated from the glycerin, the biodiesel is sometimes purified bywater to remove residual catalyst or soaps, dried, and sent to storage.

There are two type of washing the biodiesel

• Water Wash • Dry wash

Feedstock

Animal/vegetable fat

Methanol

Catalyst

Figure



catalyzed transesterification of the oil with methanol catalyzed esterification of the oil with methanol

Most of the biodiesel produced today is done with the base catalyzed reaction or with Supercritical Methanol in comparison with acid catalyzed esterfication

catalyzed transesterification of the oil with methanol

The block flow diagram shown below of the process of a base-catalyzed biodiesel process depicts typical product yields

The base catalyzed production of biodiesel generally occurs using the following steps [2]

The catalyst is typically sodium hydroxide (caustic soda) or potassium hydroxide (potash). It is dissolved in the alcohol using a standard agitator or mixer.

The alcohol/catalyst mix is then charged into a closed reaction vessel and the oil or fat is added. The system from here on is totally closed to the atmosphere to prevent the loss of alcohol. The reaction mix is kept just above the boiling point of the alcohol (around 160 °F) to speed up the reaction and the reaction takes place. Recommended reaction time varies from 1 to 8 hours, and some systems recommend the reaction take place at room temperature. Excess alcohol is normally used to ensure total conversion of the fat or oil to its esters. Care must be taken to monitor tamount of water and free fatty acids in the incoming oil or fat. If the free fatty acid level or water level is too high it mcause problems with soap formation and the separation of the glycerin by-product downstream.

complete, two major products exist: Glycerin and biodiesel. Each has a substantial amount of the excess methanol that was used in the reaction. The reacted mixture is sometimes neutralized at this step if needed. The glycerin phase is much denser than biodiesel phase and the two can be gravity separated with glycerin

simply drawn off the bottom of the settling vessel. In some cases, a centrifuge is used to separate the two materials

Once the glycerin and biodiesel phases have been separated, the excess alcohol in each phase is removed with a flash evaporation process or by distillation. In others systems, the alcohol is removed and the mixture neutralized before the glycerin and esters have been separated. In either case, the alcohol is recovered using distillation

used. Care must be taken to ensure no water accumulates in the recovered alcohol stream.

The glycerin by-product contains unused catalyst and soaps that are neutralized with an and sent to storage as crude glycerin. In some cases the salt formed during this phase is recovered for use as fertilizer. Inmost cases the salt is left in the glycerin. Water and alcohol are removed to produce 80-88% pure glycerin that is ready

e sold as crude glycerin. In more sophisticated operations, the glycerin is distilled to 99% or higher purity and sold into the cosmetic and pharmaceutical markets.

Once separated from the glycerin, the biodiesel is sometimes purified bywater to remove residual catalyst or soaps, dried, and sent to storage.

There are two type of washing the biodiesel

Process

Methyl

Ester

Process

Figure-2.1 Block diagram Of the Biodiesel Process



4th March 2011

20


Most of the biodiesel produced today is done with the base catalyzed reaction or with Supercritical Methanol in

catalyzed biodiesel process depicts typical product yields

The catalyst is typically sodium hydroxide (caustic soda) or potassium hydroxide

sel and the oil or fat is added. The system from here on is totally closed to the atmosphere to prevent the loss of alcohol. The reaction mix is kept just above the

s place. Recommended reaction time varies from 1 to 8 hours, and some systems recommend the reaction take place at room temperature. Excess alcohol is normally used to ensure total conversion of the fat or oil to its esters. Care must be taken to monitor the amount of water and free fatty acids in the incoming oil or fat. If the free fatty acid level or water level is too high it may

product downstream.

complete, two major products exist: Glycerin and biodiesel. Each has a substantial amount of the excess methanol that was used in the reaction. The reacted mixture is sometimes neutralized at this step if

diesel phase and the two can be gravity separated with glycerin

simply drawn off the bottom of the settling vessel. In some cases, a centrifuge is used to separate the two materials

separated, the excess alcohol in each phase is removed with a flash evaporation process or by distillation. In others systems, the alcohol is removed and the mixture

l is recovered using distillation used. Care must be taken to ensure no water accumulates in the recovered alcohol stream.

product contains unused catalyst and soaps that are neutralized with an acid and sent to storage as crude glycerin. In some cases the salt formed during this phase is recovered for use as fertilizer. In

88% pure glycerin that is ready e sold as crude glycerin. In more sophisticated operations, the glycerin is distilled to 99% or higher purity and sold

Once separated from the glycerin, the biodiesel is sometimes purified by washing gently with warm

Product

Methyl ester

Glycerin

Fatty matter

Methanol


Water Wash

The most common method of removing these impurities is wet washing. Wet washing away the impurities, leaving the pure biodiesel behind. But wet washing has disadvantages. It’s a timerequiring many hours for the biodiesel and water to completely separate. Wet washing can also leave residwater in the fuel. The final problem is the disposal of the hazardous effluent waste which is the by product of the wet wash[3]

Dry Wash

Dry washing is an alternative. In dry washing, an adsorbent is added that attracts and combines with impseparating them from the biodiesel. Some systems use ion exchange resins as the adsorbent, while others use a mineral called magnesium silicate, one type of which is marketed under the name Magnesol by the Dallas Group of America Inc. batch or continuous processes, removes residual methanol, providing a cost savings in the stripping step.

Advantage of dry washing

• No water-effluent stream • No emulsification • Improved oxidative stability (OSI) • Minimal yield loss • Minimal capital expenditure • Allows for continuous operation

This is normally the end of the production process resulting in a clear amberpetrodiesel. In some systems the biodiesel is distilled in an additional step to remove small amounts of color produce a colorless biodiesel.

Crude oil

Water separation

Decoloration

Soapy Paste

separation

Figure-2.2a Transesterification Layout, Oil Feedstock Pre


The most common method of removing these impurities is wet washing. Wet washing uses water as a solvent to carry away the impurities, leaving the pure biodiesel behind. But wet washing has disadvantages. It’s a timerequiring many hours for the biodiesel and water to completely separate. Wet washing can also leave residwater in the fuel. The final problem is the disposal of the hazardous effluent waste which is the by product of the wet

Dry washing is an alternative. In dry washing, an adsorbent is added that attracts and combines with impseparating them from the biodiesel. Some systems use ion exchange resins as the adsorbent, while others use a mineral called magnesium silicate, one type of which is marketed under the name Magnesol by the Dallas Group of America Inc.

tinuous processes, removes residual methanol, providing a cost savings in the stripping step.

This is normally the end of the production process resulting in a clear amber-yellow liquid with a viscosity similar to petrodiesel. In some systems the biodiesel is distilled in an additional step to remove small amounts of color

Sand filtrate

Refined

Transesterification Layout, Oil Feedstock Pre-Treatment. Source:



4th March 2011

21

uses water as a solvent to carry away the impurities, leaving the pure biodiesel behind. But wet washing has disadvantages. It’s a time-consuming step requiring many hours for the biodiesel and water to completely separate. Wet washing can also leave residual traces of water in the fuel. The final problem is the disposal of the hazardous effluent waste which is the by product of the wet

Dry washing is an alternative. In dry washing, an adsorbent is added that attracts and combines with impurities, separating them from the biodiesel. Some systems use ion exchange resins as the adsorbent, while others use a mineral called magnesium silicate, one type of which is marketed under the name Magnesol by the Dallas Group of America Inc.

tinuous processes, removes residual methanol, providing a cost savings in the stripping step. [4]

yellow liquid with a viscosity similar to petrodiesel. In some systems the biodiesel is distilled in an additional step to remove small amounts of color bodies to

Refined

Treatment. Source: Appa[17]


Supercritical Methanol Process

The need for processing cheaper feedstocks in order to decrease the high price of biodiesel has been pointed out. Some plant oils like soy and sunflower oils have a highly fluctuating price and in some years their use can be shifted from the making of biodiesel to the food market due to high international prices. Beef tallow and yellow grease are inexpensive feedstocks discarded by some industries which couhigh amounts of free fatty acids (FFA, 5-30%) and they cannot be directly processed by facilities working with the alkali catalyzed process. Many solutions have been proposed for the handli(i) pre-neutralization is easy but produces a net yield loss if the soaps are not recycled; (ii) (ii) pre-esterification of the FFA with methanol or glycerol, catalyzed by strong acids (slow), followed by

esterification in alkaline medium (fast)

(iii) Fully acid-catalyzed esterification. Acid catalysts are not as effective as the alkaline ones and take much longer reaction times, thus leading to big reactor volumes.

The process catalyzed by alkalis (NaOH, KOH) or by acids (H2SO4) need of washcatalyst. Washing is also used to eliminate glycerol and produces great amounts of effluents (3biodiesel) [6]. If washing is performed without flashing the untreated methanol the (watermust be distilled in order to recycle the methanol.

An alternative process to the catalytic ones has been recently developed by Japanese researchers comprises the one-stage transesterification with supercritical methtemperatures methanol is in a supercritical state (something that does not occur in the other conventional processes, unless a minimum threshold of 2attained [7] Reaction by supercritical methanol has some advantages:

• Glycerides and free fatty acids are reacted with equivalent rates. • The homogeneous phase eliminates diffusive problems. • The process tolerates great percentages of w

of water in the feedstock or in intermediate stage to prevent catalyst deactivation. • The catalyst removal step is eliminated. • If high methanol: oil ratios are used, total convers

The one-reactor configuration of the classical supercritical process is replaced by two supercritical reactors operating in series due to the following disadvantages

Some disadvantages of the one-stage supercritical method are clear:

• It operates at very high pressures (25• The high temperatures bring along proportionally high heating and cooling costs. High methanol: oil ratios (usually

set at 42) involve high costs for the evaporation of the

Refined

Methyl Alcohol

Glycerin purification

Metylester

Washing column

(eliminate

Reactors

Figure:-2.2b


The need for processing cheaper feedstocks in order to decrease the high price of biodiesel has been pointed out. Some ils have a highly fluctuating price and in some years their use can be shifted from the

making of biodiesel to the food market due to high international prices. Beef tallow and yellow grease are inexpensive feedstocks discarded by some industries which could be advantageously used in the making of biodiesel. They contain

30%) and they cannot be directly processed by facilities working with the alkali catalyzed process. Many solutions have been proposed for the handling of acidic feedstocks [5]

neutralization is easy but produces a net yield loss if the soaps are not recycled; esterification of the FFA with methanol or glycerol, catalyzed by strong acids (slow), followed by

um (fast)

catalyzed esterification. Acid catalysts are not as effective as the alkaline ones and take much longer reaction times, thus leading to big reactor volumes.

The process catalyzed by alkalis (NaOH, KOH) or by acids (H2SO4) need of washing steps to eliminate the dissolved catalyst. Washing is also used to eliminate glycerol and produces great amounts of effluents (3

. If washing is performed without flashing the untreated methanol the (water-methamust be distilled in order to recycle the methanol.

An alternative process to the catalytic ones has been recently developed by Japanese researchers stage transesterification with supercritical methanol, in the absence of any catalyst. At high

temperatures methanol is in a supercritical state (Tc=235 °C) and forms a homogeneous phase with the oil phase, something that does not occur in the other conventional processes, unless a minimum threshold of 2

Reaction by supercritical methanol has some advantages: [8]

Glycerides and free fatty acids are reacted with equivalent rates. The homogeneous phase eliminates diffusive problems. The process tolerates great percentages of water in the feedstock [9] catalytic process requires the periodical removal of water in the feedstock or in intermediate stage to prevent catalyst deactivation. The catalyst removal step is eliminated. If high methanol: oil ratios are used, total conversion of the oil can be achieved in a few minutes.

reactor configuration of the classical supercritical process is replaced by two supercritical reactors operating in series due to the following disadvantages [10]

supercritical method are clear:

It operates at very high pressures (25-40 MPa). The high temperatures bring along proportionally high heating and cooling costs. High methanol: oil ratios (usually set at 42) involve high costs for the evaporation of the untreated methanol.

Methyl Alcohol

Base

Decantador Metyl esther

rin purification

Glycerin evaporation

Crude glycerin

Drying phase 1

Drying phase

2

Biodiesel

Reactors

2.2b Transesterification Layout, Reaction. Source: APPA[17]



4th March 2011

22

The need for processing cheaper feedstocks in order to decrease the high price of biodiesel has been pointed out. Some ils have a highly fluctuating price and in some years their use can be shifted from the

making of biodiesel to the food market due to high international prices. Beef tallow and yellow grease are inexpensive ld be advantageously used in the making of biodiesel. They contain

30%) and they cannot be directly processed by facilities working with the alkali

neutralization is easy but produces a net yield loss if the soaps are not recycled; esterification of the FFA with methanol or glycerol, catalyzed by strong acids (slow), followed by

catalyzed esterification. Acid catalysts are not as effective as the alkaline ones and take much longer

ing steps to eliminate the dissolved catalyst. Washing is also used to eliminate glycerol and produces great amounts of effluents (3-10 wastewater litres/litre

methanol-glycerol) mixture

An alternative process to the catalytic ones has been recently developed by Japanese researchers [30]. The process anol, in the absence of any catalyst. At high

=235 °C) and forms a homogeneous phase with the oil phase, something that does not occur in the other conventional processes, unless a minimum threshold of 25% conversion is

catalytic process requires the periodical removal

ion of the oil can be achieved in a few minutes.

reactor configuration of the classical supercritical process is replaced by two supercritical reactors operating in

The high temperatures bring along proportionally high heating and cooling costs. High methanol: oil ratios (usually

Glycerin Phase

separator

Drying phase

Biodiesel

[17]


• The process as posed to date does not explain how to reduce free glycerol to less than 0.02% as established in the ASTM D6584 or other equivalent international standards.

In this sense washing cannot be eliminated because usual deglyor washing/ultracentrifugation. One-step continuous supercritical process requires large quantity of the solvent for the treatment of the feedstock as compared with the batch

The one-reactor configuration of the classical supercritical process is replaced by two supercritical reactors operating in series An intermediate step of glycerol removal between the two reaction steps is implemented in order to allow the reaction to proceed to completion with reasonably low methanol: oil ratios (6lower pressures (2.5-5.0 MPa). The low methanol: oil ratio is expected to decrease the heat duty required for the evaporation of the untreated methanol. Thethe equipment. For the pumping power, this issue is critical because in continuous running applications, it costs more to operate a pump for one year than it does to buy the pumppay for the cost of a pump in a little over a year's time. Additional recovery of heat is introduced to decrease the total heat duty of the process. Supercritical reactors are used to preheat tdownstream the reactors are used to evaporate the untreated methanol.

A removal of glycerol in biodiesel by means of adsorption in a packed bed, in this way the whole process would operate under anhydrous conditions and the issue of effluents and the water content of the glycerol by

Figure-2.3 Schematic Diagram

3. Biodiesel Production Methods

Transesterification – the process of converting vegetable oils or animal fat into biodiesel is relatively simple (compared to many other conversion technologies), is well known, and is readily available from a variety of technology providers. Numerous efforts continue to be invested to improve the process, increase yields (gallons of biodiesel produced vs. gallons of feedstocks used), improve pre-basic types of conversion systems.

Batch

Batch processing, in which feedstocks are processed in separate batches, are typically associated with smaller facilities (i.e., those with production capacities less than ~3,000,000 gallons per year). Batch operations may be more suitable for facilities targeting multiple feedstock’s in that feedstock’s would not be co

Continuous

Continuous processing, which are typically associated with larger facilities. Continuous operations tend to be more complex but more cost-effective. Cheaperreduce the cost of the production


The process as posed to date does not explain how to reduce free glycerol to less than 0.02% as established in the ASTM D6584 or other equivalent international standards.

In this sense washing cannot be eliminated because usual deglycerolization steps comprise intensive washing with water step continuous supercritical process requires large quantity of the solvent for the

treatment of the feedstock as compared with the batch-type system. [11]

reactor configuration of the classical supercritical process is replaced by two supercritical reactors operating in series An intermediate step of glycerol removal between the two reaction steps is implemented in order to allow the

d to completion with reasonably low methanol: oil ratios (6-10), lower temperatures (2505.0 MPa). The low methanol: oil ratio is expected to decrease the heat duty required for the

evaporation of the untreated methanol. The lower pressure is expected to decrease costs of pumping and of robustness of the equipment. For the pumping power, this issue is critical because in continuous running applications, it costs more to operate a pump for one year than it does to buy the pump. In some cases, a 20 percent reduction in operating costs can pay for the cost of a pump in a little over a year's time. Additional recovery of heat is introduced to decrease the total heat duty of the process. Supercritical reactors are used to preheat the reacting mixture and adiabatic flash drums downstream the reactors are used to evaporate the untreated methanol. [10]

A removal of glycerol in biodiesel by means of adsorption in a packed bed, in this way the whole process would operate conditions and the issue of effluents and the water content of the glycerol by-

Schematic Diagramtwo-Step Supercritical Methanol Process.Source:

process of converting vegetable oils or animal fat into biodiesel is relatively simple (compared to many other conversion technologies), is well known, and is readily available from a variety of technology providers.

ed to improve the process, increase yields (gallons of biodiesel produced vs. -processing techniques, and reduce capital and operating costs. There are two

in which feedstocks are processed in separate batches, are typically associated with smaller facilities (i.e., those with production capacities less than ~3,000,000 gallons per year). Batch operations may be more suitable for

feedstock’s in that feedstock’s would not be co-mingled but processed separately.

Continuous processing, which are typically associated with larger facilities. Continuous operations tend to be more effective. Cheaper feedstock’s like beef tallow and yellow grease can be used which directly



4th March 2011

23

The process as posed to date does not explain how to reduce free glycerol to less than 0.02% as established in the

cerolization steps comprise intensive washing with water step continuous supercritical process requires large quantity of the solvent for the

reactor configuration of the classical supercritical process is replaced by two supercritical reactors operating in series An intermediate step of glycerol removal between the two reaction steps is implemented in order to allow the

10), lower temperatures (250-300°C) and 5.0 MPa). The low methanol: oil ratio is expected to decrease the heat duty required for the

lower pressure is expected to decrease costs of pumping and of robustness of the equipment. For the pumping power, this issue is critical because in continuous running applications, it costs more to

. In some cases, a 20 percent reduction in operating costs can pay for the cost of a pump in a little over a year's time. Additional recovery of heat is introduced to decrease the total

he reacting mixture and adiabatic flash drums

A removal of glycerol in biodiesel by means of adsorption in a packed bed, in this way the whole process would operate -product can be reduced.

.

Shiro Saka [11]

process of converting vegetable oils or animal fat into biodiesel is relatively simple (compared to many other conversion technologies), is well known, and is readily available from a variety of technology providers.

ed to improve the process, increase yields (gallons of biodiesel produced vs. processing techniques, and reduce capital and operating costs. There are two

in which feedstocks are processed in separate batches, are typically associated with smaller facilities (i.e., those with production capacities less than ~3,000,000 gallons per year). Batch operations may be more suitable for

mingled but processed separately. [2]

Continuous processing, which are typically associated with larger facilities. Continuous operations tend to be more feedstock’s like beef tallow and yellow grease can be used which directly


4. Feedstock

It is extremely important to determine the type of feedstock to be used. This will determine the technology to be applied, and the alcohol, sub products, and final product obtained. The quality of oil used to produce biodiesel affects several aspects of the production process. If recycled oil is used, then several additional steps are needed to ensure successful biodiesel production. First, the oil must be filtered to remove any solid contaminants such as bone and other food particles. Second, the oil’s free fatty acid level and water content should be measured. The higher the cost of the feedstock, in general, the higher the production

There are two categories of raw material used for production of biodiesel:

• Non-virgin oils, such as waste vegetable oilprocessing operations (e.g., fat from renderin

• Virgin oil, such as oil from soybeans, cotton seed, or other oil

Non-virgin oil feedstocks:

Waste grease from restaurants and fat from rendering facilities typically cost less than virgin oil feedstocks. Howecompared to virgin oil feedstocks, the quality of these materials can vary significantly. Such variations in feedstock qualitnecessitate additional pre-processing prior to conversion of the material into biodiesel. In addition, these feedgenerally entail lower biodiesel yields (gallons of biodiesel per gallon of feedstock). The combination of the foregoing factors could offset some or all of the potential savings from purchase of non

The primary sources of non-virgin feedstocks:

• Waste vegetable oil (“yellow grease”) from restaurants • Rendered animal fat.[14] • Algae which can be grown using waste materials such as sewage

production.[15]

Multiple feedstocks:

It is possible for a biodiesel facility to use multiple types of feedstocks. However, like any processing operation, the wider the range of feedstocks and the wider the range of feedstock quality, the more complex and costly will be the processing. Thus, a new biodiesel facility targeting both virgin and nonprocessing for the non-virgin feedstocks in order to ensure the same level of quality of biodiesel products as that made from virgin feedstocks. It would seem more prudent for initial biodiesel production efforts to be feedstockproduction facility targeting waste vegetable oil or rendered animal fat should focus exclusively on those feedstocks (and be located as close as possible to those feedstock sources).

Virgin oil feedstock:

Virgin oil can be made from a variety of oilseed crops, although extruded or extracted Jatropha Curcas oil has been the feedstock for biodiesel produced in India.

However, almost all virgin oil is sold into edihave to compete with those existing markets for access to the vegetable oil (alternatively, new oil production supplies would be needed to meet the biodiesel demand). Moreover,fluctuations in virgin oil prices.

Feedstock yield efficiency per unit area

Crop

Rapeseed

Soybean

Jatropha

Sunflower

Coconut

Palm oil

Peanut


It is extremely important to determine the type of feedstock to be used. This will determine the technology to be applied, lcohol, sub products, and final product obtained. The quality of oil used to produce biodiesel affects several

aspects of the production process. If recycled oil is used, then several additional steps are needed to ensure successful irst, the oil must be filtered to remove any solid contaminants such as bone and other food

particles. Second, the oil’s free fatty acid level and water content should be measured. The higher the cost of the feedstock, in general, the higher the production cost of biodiesel.

There are two categories of raw material used for production of biodiesel: [12]

waste vegetable oil (WVO) from restaurants and rendered animal fats processing operations (e.g., fat from rendering facilities).

, such as oil from soybeans, cotton seed, or other oil-seed crops (e.g., rapeseed).

Waste grease from restaurants and fat from rendering facilities typically cost less than virgin oil feedstocks. Howecompared to virgin oil feedstocks, the quality of these materials can vary significantly. Such variations in feedstock qualit

processing prior to conversion of the material into biodiesel. In addition, these feederally entail lower biodiesel yields (gallons of biodiesel per gallon of feedstock). The combination of the foregoing

factors could offset some or all of the potential savings from purchase of non-virgin oil feedstocks.

eedstocks:

Waste vegetable oil (“yellow grease”) from restaurants [13]

using waste materials such as sewage and without displacing land currently used for food

possible for a biodiesel facility to use multiple types of feedstocks. However, like any processing operation, the wider the range of feedstocks and the wider the range of feedstock quality, the more complex and costly will be the processing.

iodiesel facility targeting both virgin and non-virgin feedstock would have to include substantial previrgin feedstocks in order to ensure the same level of quality of biodiesel products as that made

seem more prudent for initial biodiesel production efforts to be feedstockproduction facility targeting waste vegetable oil or rendered animal fat should focus exclusively on those feedstocks (and

e feedstock sources).

Virgin oil can be made from a variety of oilseed crops, although extruded or extracted Jatropha Curcas oil has been the feedstock for biodiesel produced in India.

However, almost all virgin oil is sold into edible oil markets. Thus, biodiesel production facilities targeting such feedstock have to compete with those existing markets for access to the vegetable oil (alternatively, new oil production supplies would be needed to meet the biodiesel demand). Moreover, biodiesel facilities have to contend with the substantial

Feedstock yield efficiency per unit area [16]

Yield (l/ha)

954

554-922

540-680

767

2151

4752

842



4th March 2011

24

It is extremely important to determine the type of feedstock to be used. This will determine the technology to be applied, lcohol, sub products, and final product obtained. The quality of oil used to produce biodiesel affects several

aspects of the production process. If recycled oil is used, then several additional steps are needed to ensure successful irst, the oil must be filtered to remove any solid contaminants such as bone and other food

particles. Second, the oil’s free fatty acid level and water content should be measured. The higher the cost of the

rendered animal fats (RAF) from meat

seed crops (e.g., rapeseed).

Waste grease from restaurants and fat from rendering facilities typically cost less than virgin oil feedstocks. However, compared to virgin oil feedstocks, the quality of these materials can vary significantly. Such variations in feedstock quality

processing prior to conversion of the material into biodiesel. In addition, these feed-stocks erally entail lower biodiesel yields (gallons of biodiesel per gallon of feedstock). The combination of the foregoing

virgin oil feedstocks.

and without displacing land currently used for food

possible for a biodiesel facility to use multiple types of feedstocks. However, like any processing operation, the wider the range of feedstocks and the wider the range of feedstock quality, the more complex and costly will be the processing.

virgin feedstock would have to include substantial pre-virgin feedstocks in order to ensure the same level of quality of biodiesel products as that made

seem more prudent for initial biodiesel production efforts to be feedstock-specific, i.e., a production facility targeting waste vegetable oil or rendered animal fat should focus exclusively on those feedstocks (and

Virgin oil can be made from a variety of oilseed crops, although extruded or extracted Jatropha Curcas oil has been the

ble oil markets. Thus, biodiesel production facilities targeting such feedstock have to compete with those existing markets for access to the vegetable oil (alternatively, new oil production supplies

biodiesel facilities have to contend with the substantial


5. Production Capacity and cost analysis

The first decision point for the design of a production unit is its capacity. For the purpose of the plant, i.e. whether it wcover only domestic needs or exports or both, as well as according to feasib

The cost parameters of a biodiesel production plant can be split up into the annual biodiesel production costs and the investment costs. As investment costs can be characterized the capital costs for the purchasing of the production equipment, the land acquisition assets and the associated infrastructure labor costs. As annual biodiesel production costs can be characterized the production inputs/output costs and the maintenance and operation costs.

The following cost analysis done base following consideration

Plant capacity:-1000ton/year

Production process: - Supercritical methanol process because of the following reasons

• Treats FFA and triglycerides • No catalyst required • Simple process and product separation • Short reaction time

Production Method:-Continuous type.

Methyl Ester Wash: - Dry wash which would save time, cost and water

Biodiesel plant to be located in India

Cost of an oil extraction plant

Operating costs: Total operating costs are estimated to amount to about 0.334 £/litrlabour can be shared with the transesterification plant o

Item

Jatropha Oil

Methanol

5 Skilled workers

3 Un-skilled worker

5 Administrative & Production Managers

Power KW/h

Repair and maintenance.

Insurance.

Quality control & administration.

Total operating costs.

Operating cost £/t (ester).

Operating cost £/litre (ester).


5. Production Capacity and cost analysis

The first decision point for the design of a production unit is its capacity. For the purpose of the plant, i.e. whether it wcover only domestic needs or exports or both, as well as according to feasibility considerations

The cost parameters of a biodiesel production plant can be split up into the annual biodiesel production costs and the investment costs. As investment costs can be characterized the capital costs for the purchasing of the production

uipment, the land acquisition assets and the associated infrastructure labor costs. As annual biodiesel production costs can be characterized the production inputs/output costs and the maintenance and operation costs.

following consideration

Supercritical methanol process because of the following reasons

Simple process and product separation

Dry wash which would save time, cost and water

: Total operating costs are estimated to amount to about 0.334 £/litre of oil extracted. It is assumed that labour can be shared with the transesterification plant or the other on-site operations

Annual Qty

1000

110

5 Administrative & Production Managers

360000

Repair and maintenance.

Quality control & administration.

Operating cost £/t (ester).

itre (ester).



4th March 2011

25

The first decision point for the design of a production unit is its capacity. For the purpose of the plant, i.e. whether it will

The cost parameters of a biodiesel production plant can be split up into the annual biodiesel production costs and the investment costs. As investment costs can be characterized the capital costs for the purchasing of the production

uipment, the land acquisition assets and the associated infrastructure labor costs. As annual biodiesel production costs can be characterized the production inputs/output costs and the maintenance and operation costs.

e of oil extracted. It is assumed that

Cost

300000

25300

12860

3600

17145

25715

7,000

3000

8500

403120

403.12

0.33


Cost of an oil extraction plant

Capital costs: The total cost of a plant with a capacity of 1000 tonnes of oil per year is estimated at 464750(£).Total operating cost per litre is 0.38£/litre

The total operating and capital cost for the proposed 1000litre of oil extracted

Total Process cost (capital + operation cost) = 0.33+0.38

Total costs

The cost of Jatropha oil after assembly and cleaning is to be £300per tonne, with an ester yield of 87% and a glycerol yield of 33%. On this basis, the total cost of bioof additives) is calculated as 0.61 £/litre

Feedstock

Capital cost.

Operating cost.

Nett glycerol value

Biod. cost ex works

7. Conclusion

The work has led to some interesting results about the state that the feasibility of the project depend on two main parameters: the raw materials cost and the biodiesel selling price

The cost of bio-diesel production from the cheapest available India is from per litre of fuel 0.61 £/litre. There can be further reduction in cost and viable if government provides subsidy. Raw material cost accounts for between 60 and 70% of the methyl estpresented here. The remaining costs could be reduced by increasing the scale of the operation. Apart from raw materials, the other factors which are shown by analysis have a significant effect on production costs are thefrom the feed-stock oil, the capital cost of plant, costs of labour and energy required.

The design and feasibility analysis of biodiesel production plant, is quite difficult to standardise the production cost and the total investment, since it depends on feedstocks, the equipment items cost, land which are subject to price fluctuations.

Items

Equipment

Building, foundations.

Transport.

Total capital costs.

Working capital (1/12 of total costs)

Capital cost £/litre (methyl ester)

Capital costs for a 1000 tonnes transesterification plant


Capital costs: The total cost of a plant with a capacity of 1000 tonnes of oil per year is estimated at 464750(£).Total

The total operating and capital cost for the proposed 1000 tonnes oil extraction plant therefore comes to about 0.634 £/

Total Process cost (capital + operation cost) = 0.33+0.38

= 0.71 £/ litre

pha oil after assembly and cleaning is to be £300per tonne, with an ester yield of 87% and a glycerol yield of 33%. On this basis, the total cost of bio-diesel produced from vegetable oil as sole feedstock (excluding the cost

Unit Cost

£/litre (ester) 0.33

£/litre (ester) 0.38

£/litre -0.10

£/litre (ester 0.61

The work has led to some interesting results about the prospects of a 1,000 tons/year biodiesel production unit. One may state that the feasibility of the project depend on two main parameters: the raw materials cost and the biodiesel selling

diesel production from the cheapest available raw materials on a scale appropriate for a startIndia is from per litre of fuel 0.61 £/litre. There can be further reduction in cost and viable if government provides

Raw material cost accounts for between 60 and 70% of the methyl ester production cost in the scenarios presented here. The remaining costs could be reduced by increasing the scale of the operation. Apart from raw materials, the other factors which are shown by analysis have a significant effect on production costs are the

stock oil, the capital cost of plant, costs of labour and energy required.

The design and feasibility analysis of biodiesel production plant, is quite difficult to standardise the production cost and ment, since it depends on feedstocks, the equipment items cost, land which are subject to price

Cost

Equipment/installation 250000

Building, foundations. 170000

Transport. 9000

Total capital costs. 429000

Working capital (1/12 of total costs) 35750

Capital cost £/litre (methyl ester) 0.38

Capital costs for a 1000 tonnes transesterification plant



4th March 2011

26

Capital costs: The total cost of a plant with a capacity of 1000 tonnes of oil per year is estimated at 464750(£).Total

tonnes oil extraction plant therefore comes to about 0.634 £/

pha oil after assembly and cleaning is to be £300per tonne, with an ester yield of 87% and a glycerol diesel produced from vegetable oil as sole feedstock (excluding the cost

prospects of a 1,000 tons/year biodiesel production unit. One may state that the feasibility of the project depend on two main parameters: the raw materials cost and the biodiesel selling

raw materials on a scale appropriate for a start-up plant in India is from per litre of fuel 0.61 £/litre. There can be further reduction in cost and viable if government provides

er production cost in the scenarios presented here. The remaining costs could be reduced by increasing the scale of the operation. Apart from raw materials, the other factors which are shown by analysis have a significant effect on production costs are the yield of ester recovered

The design and feasibility analysis of biodiesel production plant, is quite difficult to standardise the production cost and ment, since it depends on feedstocks, the equipment items cost, land which are subject to price


Acknowledgements

First of all, I wish to express my sincere gratitude to myhave inspired me, throughout and I would like wish to thank my familyenduring support, patience and understanding.

Reference

1) Biodiesel chemical reaction (online) Accessed[2.07.10]

2) Ayhan Demir (2008) “Biodiesel A realistic fuel alternative for diesel engine” London:Springer

3) Jerry W. Kram Biodiesel washing biodieselmagazine.

< http://www.biodieselmagazine.com/article.jsp?article_id=2009

4) Tom Bryan (2005) ‘Dsol absorb it all’, BIODIESEL MAGAZINE

5) Mittelbach, M., Roncar, M. (1998). Method

6) Demirbas, A. (2003). Biodiesel fuels from vegetable oils via catalytic and nontransesterifications and other methods: a survey.

7) Srivastava, A., Prasad, R. (2000). Triglyceridespp.111.

8) Madras, G., Kolluru, C., Kumar, R. 2004.

9) Kusdiana, D., Saka, S.( 2001) . Kinetics of transesterification in ramethanol, pp 693-698

10) C.R. Vera .Production of biodiesel by a twoMercosur Congress on Process Systems Engineering

11) Shiro Saka(2006)Biodiesel Production Process by Supercritical Methanol TechnologiesConference on “Sustainable Energy and Environment

12) Annett Pagan (2004) “Establishing Biodiesel Production

13) Bunkyakiat, Kunchana; "Continuous Production of BiodieselMethanol". Energy and Fuel

14) Jeremy Goodfellow Animal Fat-Based Biodiesel biodieselmagazine. (online) Accessed [28.07.10]

15) PhD thesis on “Algae production for bioenergy"

16) Y.C. Sharma (2009)‘ Development of biodiesel: Current scenario’, Renewable and Sustainable Energy Reviews 13,1646–1651

17) APPA: Associate producer of renewable energy (online)


First of all, I wish to express my sincere gratitude to my supervisor Dr Tim Short. Your enthusiasm, guidance and supporte inspired me, throughout and I would like wish to thank my family—my parents, sister, and

enduring support, patience and understanding.

Biodiesel chemical reaction (online) Accessed[2.07.10] < http://www.biofuelsystems.com/biodiesel/process.htm

Ayhan Demir (2008) “Biodiesel A realistic fuel alternative for diesel engine” London:Springer

Jerry W. Kram Biodiesel washing biodieselmagazine. (online) Accessed [28.07.10]

http://www.biodieselmagazine.com/article.jsp?article_id=2009>

Tom Bryan (2005) ‘Dsol absorb it all’, BIODIESEL MAGAZINE

Mittelbach, M., Roncar, M. (1998). Method for the preparation of fatty acid alkyl esters

Demirbas, A. (2003). Biodiesel fuels from vegetable oils via catalytic and non-catalytic supercritical alcoholtransesterifications and other methods: a survey. Energy and Management

. (2000). Triglycerides-based diesel fuels. Renewable and Sustainable Energy Reviews, 4

Madras, G., Kolluru, C., Kumar, R. 2004. Synthesis of biodiesel in supercritical fluids.

Kusdiana, D., Saka, S.( 2001) . Kinetics of transesterification in rapeseed oil to biodiesel as treated in supercritical

Production of biodiesel by a two-step supercritical reaction process with Adsorption refining,pp.2 4thMercosur Congress on Process Systems Engineering

iesel Production Process by Supercritical Methanol Technologies The 2nd Joint InternationalConference on “Sustainable Energy and Environment

Biodiesel Production”

Bunkyakiat, Kunchana; "Continuous Production of Biodiesel via Transesterification from Vegetable Oils in Supercritical

Based Biodiesel biodieselmagazine. (online) Accessed [28.07.10]

PhD thesis on “Algae production for bioenergy" Murdoch University, Western Australia

Y.C. Sharma (2009)‘ Development of biodiesel: Current scenario’, Renewable and Sustainable Energy Reviews 13

APPA: Associate producer of renewable energy (online) Accessed[16.07.10]



4th March 2011

27

Dr Tim Short. Your enthusiasm, guidance and support my parents, sister, and all of my friends for their

http://www.biofuelsystems.com/biodiesel/process.htm>

Ayhan Demir (2008) “Biodiesel A realistic fuel alternative for diesel engine” London:Springer

catalytic supercritical alcohol

Renewable and Sustainable Energy Reviews, 4,

peseed oil to biodiesel as treated in supercritical

step supercritical reaction process with Adsorption refining,pp.2 4th

The 2nd Joint International

via Transesterification from Vegetable Oils in Supercritical

Based Biodiesel biodieselmagazine. (online) Accessed [28.07.10]

Y.C. Sharma (2009)‘ Development of biodiesel: Current scenario’, Renewable and Sustainable Energy Reviews 13

Developpment of a biodiesel production plant by Prasad Ramesh Patil is licensed under a Creative Commons Attribution-ShareAlike 3.0 Unported License.

Documents

Development of a biodiesel production plant