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BioDiesel Plant
IMMEDIATELY AVAILABLEIMMEDIATELY AVAILABLEFROM IPPFROM IPP
5 MM Gallons/Year
Brief OverviewBrief Overview
Capacity: 5,000,000 gallons/year
Byproduct: 10% or 500,000 gallons/year of Crude Glycerine
Built: 2007
Shutdown: 2009
Product: B100 BioDiesel or Crude Glycerine
Raw Materials: Soybean Oil or Animal Tallow, Methanol
PLANT OPERATED FOR ONLY 17 MONTHS
B100 B100 BioDieselBioDiesel FactsFacts
B100 Biodiesel is a renewable, cleaner burning diesel fuel made from vegetable oil or animal tallow.
Technically speaking, biodiesel is called methyl ester or ethyl esters.
Take vegetable oil and strip out the glycerin molecule and replace it with three alcohol molecules.
Simply put, Biodiesel is vegetable oil modified with a lower viscosity to fool your diesel injection system to think it's still pumping petrol diesel.
Biodiesel can also be produced from animal tallow.
B100 is 100% pure neat biodiesel. No Diesel
Major EquipmentMajor Equipment
Carbon Steel Storage Tanks (12)12,000 gallon capacity, carbon steel, 12’ diameter by 20’ tall with flat top and bottom. Five tanks have external steam heating on the lower 4’ of surface area. Used for raw material, product, and intermediate storage. Built in 2006 by Modern Welding Company.
Stainless Steel Storage Tank (1)12,000 gallon capacity, stainless steel, 12’ diameter by 20’ tall with flat top and bottom. Enclosed in an internal cinder-block room with foam fire protection system. Used for methanol storage. Built in 2006 by Modern Welding Company.
Foam Fire Suppression System (1)Buckeye Fire Equipment Company model VBT-300 with 300 gallon capacity foam tank. Viking model F-2 deluge valve with Notifier® model NFS3030D/ND intelligent fire information and control panel. For methanol storage tank only.
Alfa Laval Centrifuges (2)Disc stock type separator – model PX-30. 7.5 hp electric drive, 608 gal/hr capacity, constructed of 316 SS.
Major EquipmentMajor Equipment
Separators Inc Centrifuge (1)Model MAP-205 with bowl speed of 8750 rpm.
Vacuum Dryers (2)200 gallon capacity, carbon steel, with Nash Elmo vacuum pump type 4HF50/4 (7.5 hp motor).
Vertical Pressure Leaf Filters (4)With Lightnin tank agitator and Optex Control 4000 digital control panel. Dome equipped with latch bolt and dogs for quick access. Built by Sharplex of India.
Disc Mixer (1)304 stainless steel with electric drive motor.
Spirax Sarco® Pressure Powered Pump™ Packages (2)Integral pump and receiver assembly with simplex horizontal cylinder 14” diameter by 42”long. Pump is 6” X 4” X 2”.
Major EquipmentMajor Equipment
Reactors (2)820 gallon capacity carbon steel with domed top and bottom. External steam jacketing on lower 60% of vessel. Lightning agitator.
Settling Tanks (2)2,500 gallon capacity carbon steel with domed top and bottom. CR5 electric pump mounted below tank.
Acidulation Tank (1)500 gallon 316 stainless steel with domed top and bottom. Lightnin agitator. Wilden air operated pump and CR3 electric pump mounted below tank.
Distillation Columns (3)Part of distillation design package from India. 316 stainless steel with carbon steel skirt. One packed and two trayed columns.
Distillation Column Reboilers (3)Shell and tube units. Part of distillation design package from India. 316 stainless steel.
Major EquipmentMajor Equipment
Distillation Column Condensers (3)Plate and frame units from Tranter of India. Part of distillation design package from India. 316 stainless steel plates.
Boiler (1)Donlee Technologies steam packaged boiler 500 series model number SPH-200-N/2 200175. 8,625 lb/hr of 150 psig steam. Power Flame Burner model C5-GO-30B forced air burner system. Natural gas fired. Included 1,500 gallon stainless steel water supply tank, blow-down tank, water treatment station with metering pump. Built in 2001.
Air Compressor (1)Champion/Riverside reciprocating air compressor. Three-cycle powered with a Marathon 10 hp electric motor on a 120 gallon horizontal receiver.
Air Dryer (1)Pneumatech® non-cycling refrigerated air dryer model number ADA-40 989422.
Major EquipmentMajor Equipment
Cooling Tower (1)Marley AV series, model AV62041G, built in 2006.
Chillers (2)Schreiber model 2000ACM. 440 volt. 20 tons refrigeration each.
Baghouse (1)United Air Specialists model BDC-21C.
Process DescriptionProcess Description
B100 refers to pure or 100% biodiesel. Blends are referred to using this designation. For instance, B20 would be a blend of 20% biodiesel and 80% petroleum-based diesel. This plant ran with three operators per shift.
The raw material for this process is typically soybean oil, although animal fat can also be used. If it is not pure enough, the soybean oil is typically run through a pre-treatment area of the plant prior to being used in the reactor. This area consists of centrifuge, drying, and filtering (pressure leaf filter) unit operations. The centrifuges in this system are Alfa Laval model PX-30 disc stock type separators with 608 gal/hr capacity each. They have 7.5 hp electric drives and are constructed of 316 SS. The vacuum dryers in this system are 200 gallon capacity carbon steel vessels with Nash Elmo vacuum pumps (type 4HF50/4 with 7.5 hp motor) pulling vacuum from the top of the vessels.
The vertical pressure leaf filters in this system were built by Sharplex of India and have Lightnintank agitators and Optex Control 4000 digital control panels.
Process DescriptionProcess Description
The tank farm consists of 12 carbon steel tanks and one stainless steel tank with 12,000 gallons capacity each. The carbon steel tanks are used for raw materials, intermediate, and finished products. The stainless steel tank is for methanol storage, and it has a foam fire suppression system installed around it.
The purified raw material is then mixed with methanol and sodium methylate (also called sodium methoxide) in the two trans-esterification reactors. The product is heated to 90°C under atmospheric pressure and agitation. This is a batch process which takes about two to three hours of reactor time to complete the reaction. This technology is theoretically able to run continuously through the reactor, but a continuous mode of operation was never accomplished at this location. The two reactors are 820 gallon capacity carbon steel vessels with steam jacketing and Lightnin agitators.
Sampling is performed to determine when to transfer the reactor contents into the two settlers. In the settlers, sulfuric acid is added to stop the reaction. The glycerine byproduct is removed from the bottom of the settlers, and the biodiesel flows over the top. The two settlers are 2,500 gallon capacity carbon steel vessels.
Process DescriptionProcess Description
The crude glycerine byproduct production is equal to about 10% of the biodiesel produced. The crude glycerine can simply be run through the glycerine column to recover the unreactedmethanol, or it can be sent through a more intensive process for purification to “technical grade”glycerine (98% pure). The glycerine column is a trayed, stainless steel column with bottoms pump, reboiler, and overhead condenser.
The biodiesel leaving the top of the settler proceeds to the biodiesel column where unreactedmethanol is recovered from the column overheads and is sent to the methanol column for cleanup prior to recycling back to the reactor. The biodiesel column is a packed, stainless steel column with bottoms pump, reboiler, and overhead condenser.
The biodiesel from the bottom of the biodiesel column is heated and washed with water in an in-line mixer and agitated storage tank prior to entering the centrifuge. Water and solids are removed by the centrifuge and the biodiesel then goes to the vacuum dryer. This is simply a 200 gallon drum with a vacuum pump on the overheads. Most of the remaining water is removed here, and the biodiesel moves on to the pressure leaf filter. Diatomaceous earth and filter aid are added prior to the pressure leaf filter. This is a vertical pressure leaf filter by Sharplex of India with a Lightnin tank agitator and an Optex Control 4000 digital control panel.
Process DescriptionProcess Description
The biodiesel now goes through some bag filters for final polishing and is then stored in 12,000 gallon carbon steel storage tanks. The bag house is a model BDC-210.
The distillation package was designed and fabricated in India. It consists of three stainless steel distillation columns with stainless steel reboilers (shell and tube) and overhead condensers (plate and frame). Each column has at least one bottoms pump. Two of the columns have trays and one is packed. Vacuum for distillation is provided by steam driven ejectors. The unreactedmethanol is recovered in one of these trayed columns.
Product is loaded using ground-level loading arms since all of the trucks are bottom loading for this facility. The automatic loading utilizes Contrec and Scully load control systems.
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Contact InformationContact Information
MICHAEL JOACHIMDIRECTOR, PLANTS DEPT.Tele: 609-838-5930 (direct)
Mobile: [email protected]
SANJEEV REGEVP GLOBAL PLANT SALESTele: 609-838-5938 (direct)
Mobile: [email protected]
