BiodieselFrom Field To Fuel

Lance Hall

Biodiesel Basics

What is “Bio”- diesel?

• Biodiesel is a renewable resource based fuel for use in Diesel engines.

• It can be made from various oils including corn, soybean, canola, cottonseed, peanut, etc. and from animal fats.

• A more scientific term is Fatty Acid Methyl Ester (FAME).

• The oils and fats contain triglycerides (TGs) that are chemically converted into FAME by a process called “transesterification”.

• The fuel produced is more environmentally friendly than petroleum diesel (dino-diesel).

What is “Bio”- diesel?

Drawbacks of Using Biodiesel

• Will VOID warranty on most new vehicles

• Cold weather causes the biodiesel to gel at a higher temperature than dino-diesel– A blend of Biodiesel and dino-diesel should

be used in colder weather

• Additives used currently in dino-diesel may have little or NO effect on 100% biodiesel

• Will clog injectors in less time

• Tax Issues

Benefits of Biodiesel

• Less dependant on oil, domestic or foreign

• Renewable, from soybeans in the US, canola in Canada, rapeseed in Europe, palms in Indonesia – many sources in many places

• Once properly processed, it is GRAS (Generally Regarded As Safe)

• Helps the engine with its lubricativeproperties

How to Use Biodiesel

• Just like regular Diesel Fuel!

• Modifications to engine:

– Possibly replace rubber hoses with synthetic lines on older vehicles.

– Otherwise, generally none.

Biodiesel Safety

First Step is Knowledge

• Knowledge of the potential hazards

• Knowledge of the chemicals, READ ALL MSDSs!

• Knowledge of your own capabilities, know your limits of time, space, money, physical and mental capacity.

• Knowledge of the process

Safety Concerns

• An alcohol MUST be used in the reaction– Methanol (Methyl Alcohol)

• Less expensive, more poisonous

– Ethanol (Ethyl Alcohol)• More expensive, less poisonous

• Both alcohols are HIGHLY FLAMMABLE!– NO Smoking, open flame, sparks or other

heat source!

• Rinse exposed areas with water

Safety Concerns

• Typically a catalyst is used to aid the reaction.

• Catalyst are generally either Sodium Hydroxide (NaOH) or Potassium Hydroxide (KOH).

• Both can cause severe burns when in contact with skin, eyes, etc.

• Rinse exposed areas with copious amount of water

Safety Concerns

• The oil can be a danger, an oily floor can cause serious danger.

• If oil is spilt, clean immediately with soap and water

Methanol Hazards

• Read MSDS (Material Safety Data Sheet)

• Hazards include, but are not limited to:

– Blindness

– Death

• Is readily absorbed through the skin, you don’t have to drink it to suffer the effects!

Catalyst Hazards

• Both common catalysts are very strong bases (alkaline).

• Both are very strong corrosives, will cause steel to rust very quickly.

• Both are caustic, will burn living tissues if not washed thoroughly and immediately.

Safety Equipment is A MUST!

• Wear Personal Protection Equipment (PPE) when handling the hazardous materials mentioned previously

– Gloves

– Apron

– Faceshield

– Respirator

– Fire Extinguisher

Making Biodiesel

Basic Steps for Biodiesel

• Collect Oil• Strain Oil• Heat Oil• Filter Oil• Titrate Oil (if using WVO)• Mix catalyst and methanol (“methoxide”)• Mix “methoxide” and oil• Let biodiesel and glycerin separate• Decant glycerin layer• Recover Methanol from biodiesel, if possible• Wash biodiesel• Dry biodiesel (Let water settle or evaporate out)• Filter biodiesel• Recover Methanol from glycerin, if possible• Find a good way of using or disposing glycerin

O O

|| ||

CH2 - O - C - R1 CH3 - O - C - R1

|

| O O CH2 - OH

| || || |

CH - O - C - R2 + 3 CH3OH → CH3 - O - C - R2 + CH - OH

| (Catalyst) |

| O O CH2 - OH

| || ||

CH2 - O - C - R3 CH3 - O - C - R3

Methanol KOH/NaOHTriglyceride Biodiesel Glycerol

Basics of Biodiesel Chemistry

Biodiesel Production Methods

• For the “homebrewer”

– Common Base-Catalyzed Reaction

– Two Stage Base-Catalyzed Reaction

– Acid-Base Reaction

• Advanced Methods

– Supercritical Methanol Reaction

– Other Continuous Processes

Your First Batch

• Make a small batch using virgin oil.

• Recipe:– Heat one quart of the oil of your choice to

approximately 120°F

– Mix 5 grams (0.176 oz) of NaOH or 7 grams (0.246 oz) of KOH in one pint (18%-25% of the oil volume) of Methanol. Make sure the catalyst is completely dissolved.

– Add “Methoxide” to oil and stir using stir plate or blender for 10 minutes

Demonstration #1

Making Biodiesel with Virgin Vegetable Oil

• After mixing, leave it alone for an hour!

• If the steps were performed correctly there will be a layer of glycerin on the bottom of the glass, you may need to look closely at first to see it.

Your First Batch

It should look like this.

Biodiesel

Glycerin

Sample of Olive Oil

Washing

• Washing removes soaps formed in the reaction, excess catalyst and methanol.

• Pour the half of the biodiesel into another similar sized container, try not to pour any of the glycerin in with it.

• Pour an approximately equal volume of distilled water in with the biodiesel and shake gently.

• The biodiesel and water will eventually separate, it may take days for the biodiesel to completely clear, so be patient.

Washing

Biodiesel on top of Water

After Mixing Biodiesel and water separating

Layers after Separation

Biodiesel

Soap Layer (Very Thin

White Layer)

Water (and more!)

Drying the Fuel?

• Drying refers to the removal of the water suspended in the fuel.

• Methods:– Waiting for the water to settle out and

evaporate out.

– Bubble drying

– Other more advanced techniques

• Biodiesel should be a clear amber color after drying and should be ready to use!

Using Waste Veggie Oil (WVO)

• Pros

– More Economical

– Recycling

• Cons

– Finding a source can be difficult

– Messy

– Titration

Titration

• Necessary for determining the amount of base required to neutralize the FFAscreated by cooking with the oil.

• Assuming you’re using the one step base-catalyzed method.

– Other methods may not use titrations!

• Practice on a small quantity just as before.

Titration Materials/Chemicals

• Chemicals

– WVO, of course

– Isopropyl Alcohol (sold as Iso-Heet)

– 0.1% Titration solution

• 1 gram of NaOH or 1 gram of KOH in 1 liter water

• 0.03338 ounces of NaOH or 0.03338 ounces of KOH in 1 quart of water

– Phenolphthalene Solution

Titration Materials/Chemicals

• Materials

– Syringe for WVO

– Syringe for titrant solution

• Burette is much more accurate

– Syringe for Isopropyl alcohol

• Small graduated cylinder is more accurate

– Small jar or beaker to contain liquids

Performing the Titration

• Starting with the clean beaker (or jar).

• Add 10 milliliters (0.338 fluid ounces) of Isopropyl alcohol

• Add 3-5 drops of the Phenolphthalene

• Add 1 milliliter (0.0338 fluid ounces) of WVO

• Mix well until the oil is dissolved into the Isopropyl alcohol

Performing the Titration

• Add 0.25 milliliters of titrant solution to oil mixture

• Mix well

• Repeat previous 2 steps until the mixture remains pink/purple for longer than 30 seconds.

• KEEP TRACK OF TOTAL AMOUNT OF TITRANT SOLUTION ADDED TO MIXTURE, this number is the entire reason for performing a titration!!

Calculations

• Start with either 5 grams of NaOH or 7 grams of KOH per liter of WVO

• Add the value determined by the titration

• Make sure you are using the same catalyst as you used in the titration

Example #1

• You’re oil is in relatively good condition and the WVO titrated to 1.25 milliliters of titrant solution and you’re using KOH

7 grams + 1.25 grams = 8.25 grams per liter

So, for 10 gallons (37.8 liters)

8.25 grams per liter multiplied by 37.8 liters means a total of 311.86 grams of KOH will be mixed with the methanol

Example #2

• You’re oil is in relatively bad condition and the WVO titrated to 4.75 milliliters of titrant solution and you’re using NaOH

5 grams + 4.75 grams = 9.75 grams per liter

So, for 20 gallons (75.6 liters)

9.75 grams per liter multiplied by 75.6 liters means a total of 737.1 grams of NaOH will be mixed with the methanol

Your First WVO Batch

• Perform same steps as before with 1 quart of strained WVO instead of virgin oil.

• Use value from titration for amount of catalyst to mix with the pint of methanol

– Remember to use consistent units.

Demonstration #2

Making Biodiesel Using WVO

Biodiesel Calculator1 Enter assumptions and values here

NaOH the base amount of catalyst needed 5.00

KOH the base amount of catalyst needed 6.50

Methanol use this much methanol for each unit of oil 20.00%

2 Pick your catalyst

KOH 6.5 grams per liter of oil

Purity of your catalyst 98.0%

3 Titration values

Enter the value you determined by titration 1.75

4 How much oil you'll use

I'm going to use this much oil 30

5 So, here's what you'll need

Liters … or, the equivalent in gallons

METHANOL 22.71 6.00

Grams … or, the equivalent in ounces

KOH 956.0 33.75

Liters Gallons

So, You’ve Made Biodiesel

Next Step, Build a Reactor!

Building a Biodiesel Reactor

Building a Reactor

• Generally at least two vessels.

– Main reactor vessel

– “Methoxide” vessel

• Methoxide is an errant term used in the biodieselcommunity and refers to the mixture of methanol and catalyst. True sodium methoxide is a very dangerous chemical that is used in the industry and provides better reactions.

Building a Reactor

• Pump(s)

• Hoses, fittings, hose clamps

• Valves

• Oil source for Waste Veggie Oil (WVO).

• Thermometer capable of reading over 120°F

• The sky is the limit for the reactor, but maybe not the oil supply.

Other Equipment

• Oil Heater

• Titration equipment

– Syringes

– Burette*

– Phenolphthalene Indicator Solution

– Isopropyl Alcohol 99%

• Scales to weigh Catalyst

• Magnetic stirring hot plate* or blender

The Main Reactor

• 60 Gal. Full Drain

• Polyethylene

• With Stand ~$225

Methoxide Tank

• 15 Gallon

• Polyethylene

• With Stand ~$100

• Notice 12V Automotive Style Methanol-safe fuel pump in top left of picture

Pump(s)

• 330 Gal. per Hour

• 1” NPT Fittings

• Cost: ~$25.00

• Power Switch

Hoses, Fittings and Clamps

• Water resistant Polyurethane 1” ID Hose

– Cost: ~$3.44/Ft

• Nylon or PVC* 1” Barb fittings

– Cost: Various

• Stainless Steel worm-drive clamps

– Cost: ~$7 per 10-pack

Valves

• 1” Brass Ball Valves

• Male NPT to Female NPT

• Cost: ~$16 each

Heaters

• In-Line Model

• High Watt Density*

• Added Switch for Convenience

• Cost: ~$300.00

• Care must be taken to turn Heater off when there is no flow of fluid!

Filtering System

• You can’t filter too much

• For WVO: 200 micron heated recirculation followed by 100 micron in storage tank.

• For Biodiesel: 25 micron recirculation followed by 1 micron in storage tank.

200 micron filter bag for WVO

100 micron filter bag for WVO in

storage tank

Titration Equipment

Burette

Isopropyl Alcohol

Beaker

PhenolphthaleneSolutionSyringe

Titrant Solution

Magnetic Stirring Hot Plate

Scales

• Electronic Scales

• Resolution of 0.01 grams

• Cost: Varies

Magnetic Stirring Hot Plate

• 8” x 8” Surface

• Stir and heat controls

• Teflon Coated Stir Bars

• Cost: Varies

My Car

• 2003 Volkswagen Jetta GLS TDI

– TDI is an acronym for Turbo Direct Injection

• 90hp/155ft-lb 1.9L 4 cylinder engine with 5-speed manual transmission

• 46-48 miles per gallon on either fuel

– I drive 70 miles per day or about 2000 miles per month – less than 50 gallons of fuel per month

Helpful Literature, Websites

• www.journeytoforever.org

• “How to make Biodiesel” by Carter & Halle

• http://www1.eere.energy.gov/biomass/document_database.html, search “biodiesel” in the keyword box

• “Biodiesel-O-Matic” calculator from http://www.biodieselcommunity.org/recipecalculator/biodiesel-o-matic.xls

• “Converter” - Unit converter program from http://joshmadison.com/software/convert/download.php

• The internet is a valuable resource, but use discretion.

Extra Tax Info

Biodiesel IS Taxable if used on public highways!Must be licensed and bonded! (Minimum $1000 Bond)Good news: once you are licensed and bonded then you can also sell to other

individuals.

Alabama Department of RevenueSales, Use & Business Tax DivisionMotor Fuels SectionP O Box 327540Montgomery, AL 36132-7540(334) 242-9608 Phone(334) 242-1199 Fax

Steve DuBose, ManagerMotor Fuels Section

http://www.revenue.alabama.gov/motorfuels/index.html