Biodiesel 1

VEGETABLE OILS AS FUELS “ THE USE OF VEGETABLE OILS FOR ENGINE FUELS MAY SEEM INSIGNIFICANT TODAY. BUT SUCH OILS MAY BECOME IN COURSE OF TIME AS IMPORTANT AS PETROLEUM AND COAL TAR PRODUCTS OF THE PRESENT TIME” - Rudolf Diesel at the Engg Society of St. Louis,

Transportation Energy Demand Total delivered energy consumption for transportation was 27.8 quadrillion Btu in 2004 This accounted for over 25% of the entire U.S. energy consumption Projected to reach 39.7 quadrillion Btu in

The Alternative Biodiesel is a cleaner burning replacement fuel made from renewable sources like new and used vegetable oils and animal fats Low-level blends (≤20% biodiesel) can be used in almost any existing diesel engine High-level blends (>20% can be used in most new diesel engines 4

Overview of Biofuel Production Technologies First Generation of Biofuels 5

Overview of Biofuel Production Technologies Second/Third Generation Biofuels 6

Biomass to high added value chemicals Biomass Extraction of chemicals Biodiesel production Glycerol Sugar fermentation Thermochemical conversion Ethanol Lactic acid Chemicals Proteins Vitamins Fragrances Pharmaceuticals Bio-SNG Chemicals 7

Biofuel/biofuel production technology selection criteria Technological criteria (energy content, non renewable Financial criteria (static, dynamic, risk) Environmental criteria (CO 2, CO, NO x, SO 2, etc.) Socio-economic criteria Energy consumed, availability, carbon residue, sulfur content, viscosity, density, efficiency, scale up, …) 8

Comparison of technologies Economic versus environmental aspects Source: IEE Leipzig,

Why make biodiesel? Diesel fuel injectors are not designed for viscous fuels like vegetable oil Glycerin (thick) Biodiesel 10

** B100 (100% biodiesel) with NOx adsorbing catalyst on vehicle Relative emissions: Diesel and Biodiesel Total Unburned HCs CO Particulate Matter **NOx Sulfates PAHs n-PAHs Mutagenicity CO2 Percent B100 ** B20 Diesel 11

The Chemistry of Biodiesel All fats and oils consist of triglycerides – Glycerol/glycerine = alcohol – 3 fatty acid chains (FA) Transesterification describes the reaction where glycerol is replaced with a lighter and less viscous alcohol – e.g. Methanol or ethanol A catalyst (KOH or NaOH) is needed to break the glycerol-FA bonds 12

Biodiesel – General Definitions Biodiesel is renewable fuel for diesel engines derived from fats and oils such as soybeans and animal fats. Biodiesel can be used in any concentration with petroleum-based diesel fuel in existing diesel engines with little or no modification. Biodiesel is not raw vegetable oil! Biodiesel must be produced by a chemical process that removes glycerin from the oil. Biodiesel blend, n. -- a blend of biodiesel fuel meeting ASTM D 6751 with petroleum-based diesel fuel designated BXX, where XX is the volume percent of biodiesel. 13

14 Biodiesel Facts Lower energy content than Diesel – Biodiesel: 118,296 BTUs per gallon – No. 2 Diesel: 129,500 BTUs per gallon Source: National Biodiesel Board Energy Lifecycle – 3.2 units of energy are produced for each energy unit used Source: NREL

15 Biodiesel Facts What type of oil is most biodiesel made from? – Soybean oil in the USA – Rapeseed oil in Europe – Jatropha oil in Indonesia ? Is biodiesel the same as vegetable oil? – No!

16 Will biodiesel damage my engine? – No…if the biodiesel meets the standards of ASTM 6751 – One exception: Biodiesel can damage certain natural rubber engine components over time – Older engines may require the replacement of fuel lines and some gaskets – These components are unlikely to fail immediately but may fail with increased biodiesel use

Biodiesel Background Four main production methods – Direct use and blending – Micro emulsions – Thermal cracking – Transesterification Transesterification – Most common production method – Uses vegetable oils and animal fats as feed stocks – The reaction of a fat or oil with an alcohol to form esters (biodiesel) and glycerol 17

Base Catalysed Transestrification Most popular of all method >90% of all bio diesel by this method Low temperature ( 150o F) and pressure (20 PSI) High conversion (>98%) Minimum side reactions Direct conversion- No intermediate step Ordinary material of construction 18

Schematic of the Transesterification process 19

BIODIESEL – Final Product Biodiesel 100% Glycerin 20

Biodiesel Process Flow Diagram 21

Energy Crop R&D Farming Oilseed Meal Crushing Crop Oil Biodiesel Production Biodiesel Market Glycerin From the Farmer to the Fuel Tank 22

Vegetable Oil as Feedstocks Oil-seed crops are the focus for biodiesel production expansion Currently higher market values for competing uses constrain utilization of crops for biodiesel production Most oil-seed crops produce both a marketable oil and meal – Seeds must be crushed to extract oil – The meal often has higher market value than the oil 23

24 Oilseeds and Oilseed Processing

25 Types of Oilseeds Major Oilseed Crops – Soybean – Cottonseed – Sunflower – Canola/Rapeseed – Flaxseed – Safflower

26 Other oil producing crops – Corn – Peanut – Camelina – Palm – Olive – Coconut

27 Oilseed Crops: 2007 Yields CropAve. YieldAve. Oil Content Soybeans41.7 bu/acre ≈ 22% Canola1,250 lbs/acre ≈ 40% Flaxseed16.9 bu/acre ≈ 38% Safflower1,215 lbs/acre ≈ 35% Sunflower1,436 lbs/acre ≈ 42% Mustard603 lbs/acre ≈ 36%

28 Oilseed Processing The Oilseed Processing Industry: – Separates the “whole seed” into 2 or more products – The difference between the cost of the seed and the value of the products created is the “crushing margin”

29 Oilseed Processing Technology Two General Methods – Solvent Extraction Standard technology for facilities with daily capacities of greater than 300 tons per day Commonly used in conjunction with some form of mechanical extraction – Mechanical Extraction Typically used for facilities with daily capacities of less than 150 tons per day

30 Solvent Extraction The basic process: – Seed Preparation Removal of foreign objects Removal of seed hulls or shells for some seeds – Pre-Pressing Seed is crushed through a mechanical press – Pre-Pressing removes some oil from high oil content seeds

31 – Solvent Application Solvent is applied to the pre-pressed material The solvent bonds to the oil in the material – Solvent & oil mixture is removed from the meal – The oil is then separated from the solvent which is reused in the process

32 Solvent Extraction Benefits: – Solvent Extraction is capable of recovering of 99% of the oil contained in the seed – Lowest cost per ton for commercial processing Challenges: – Large capital investment – Not feasible for small-scale processing – Environmental concerns

33 Mechanical Extraction The basic process: – Seed Preparation Removal of foreign objects Removal of seed hulls or shells for some seeds – Extraction Seed is processed by a mechanical press – Removing 65-80% of oil contained in the seed

34 Required Equipment – Mechanical Press – Power source for the press – Seed Bins – Meal Bins – Oil Tanks – Pumps, Filters, Plumbing

35 On-Farm Example: – If you plant 100 acres of canola, – with an average yield of 1,100 lbs per acre, – your production is approximately 55 tons

36 The 55 tons of seed will yield approximately: – 4,200 gallons of oil – 36 tons of meal * Assuming: The seed has 38% oil content and press recovers 75% of the oil content in the seed.

37 On-Farm Example: – If you plant 100 acres of safflower, – with an average yield of 800 lbs per acre, – your production is approximately 40 tons

38 The 40 tons of seed will yield approximately: – 2,800 gallons of oil – 27 tons of meal * Assuming: The seed has 35% oil content and press recovers 75% of the oil content in the seed.

39 Biodiesel Production Technology

40 Biodiesel Process Basic Overview – Inputs: Oil, Alcohol & Catalyst – Outputs: Biodiesel & Crude Glycerin

41 Sample Recipe – Oil100 Parts – Alcohol10 to 20 Parts – Catalyst0.5 to 3 Parts * Manufacturers often provide a “basic” recipe to use as a starting point.

42 Outputs – Biodiesel100 Parts – Crude Glycerin10-20 Parts

43 Pre-Reaction Equipment – Oil Storage Tank – Alcohol Storage Tank – Catalyst Storage – Biodiesel “Reactor” – Pumps, Filters, Plumbing

44 Post-Reaction Equipment – Settling tanks and/or Separating Equipment – Washing Equipment – Drying Equipment – Biodiesel Storage Tank – Glycerin Storage Tank – Pumps, Filters, Plumbing

45 Biodiesel Equipment – Micro Scale Processors 100 gallons or less per batch Numerous Manufacturers Some sold as “kits” Others sold as “ready to use” Accessories included in the package varies

46 Micro Scale Biodiesel Processor

47 Biodiesel Equipment – Small-Scale Processors 75 to 300 gallons per batch Fewer Manufacturers Usually not sold as “kits” Typically higher quality materials Accessories included in the package varies

48 Small-Scale Biodiesel Processor

49 Processing 4,200 Gallons – 40 gallon processor: 105 batches – 60 gallon processor: 70 batches – 100 gallon processor: 42 batches

50 Final Products Biodiesel – On-Farm Use Blended Fuels Fuel Quality Important Vehicle Modifications – May need to replace natural rubber fuel lines and gaskets

51 Crude Glycerin – No Ready Market for Crude Glycerin – Quantity produced is 10% to 20% of biodiesel production – Contains Methanol & Catalyst – Possible Uses: Compost Fuel Oil Refine to Pharmaceutical Grade Glycerin

52 Government Involvement: Regulations, Incentives & Policies

53 What agency is responsible for biofuel policy? – A) Energy – B) Agriculture – C) Commerce – D) Environmental Protection – E) Transportation

54 Biofuels Policy Current govt. policy for biofuels: – Most of the biofuels policy is: Farm Energy Energy Policy – Other agency are involved: Dept. of Transportation Environmental Protection Agency Internal Revenue Service Department of Labor

Government Policy – Reduce nations dependency on foreign oil – Requires certain policies – Several grant programs – Investment opportunities in certain refueling infrastructure 55

56 Other Regulations Fire Safety Issues – Methanol storage is subject to regulations of local fire marshals. Contact your local fire marshal Building Code Issues – Production and storage of biodiesel, methanol and glycerin may violate building codes.

57 Economics of Biodiesel Production

58 Oilseed Processing Oilseed Processing Assumptions – Seed Cost$0.151 per pound – Oil Content 40% – Recovery Rate72% Consistent with an average mechanical crush – Labor Cost$10/hour – Meal Revenue$120 per ton Net of transportation costs 60-70% of the cost to process biodiesel is from feed stock costs

59 Assume 10 ton per day press – Installed Cost of $11,485 – Financed for 10 years at 6% Labor Cost$3,28947% Other Costs$3,70453% Total Cost$6,993 Processing Cost per Ton$51

60 Seed 274,110 $0.151 per lbs. Crushing 137 $51 per ton Meal92.7 $120 per ton Oil 10,000 gallons Seed Cost$41,391 Crushing Cost$ 6,993 Total Cost$48,384 Meal Revenue$11,124 Net Cost$37,260 Net Cost Per Gallon of Vegetable Oil $3.73

Technological Challenges Expensive feed stocks and inefficient production methods Strict standards for product quality NO x emissions Transportation and storage concerns 61

Storage Biodiesel should be stored 5-10 degrees F above cloud point. Above ground fuel systems should be protected with insulation, agitation, heating systems, or other measure. Test Method Cloud Point ASTM D2 500 Pour Point ASTM D97 Cold Filter Plug Point IP 309 B100 Fuel oFoF oCoC oFoF oCoC oFoF oCoC Soy Methyl Ester Canola Methyl Ester Lard Methyl Ester Edible Tallow Methyl Ester Inedible Tallow Methyl Ester Yellow Grease 1 Methyl Ester Yellow Grease 2 Methyl Ester

ASTM D 6751 – Biodiesel Fuel Specification Fuel quality is of the utmost concern and importance to the biodiesel industry. ASTM D 6751 is the specification for biodiesel fuels irrespective of the feedstock source and/or processing method. Standard ensures safe operation in a compression ignition engine. 63

Transportation Should not be contaminated Trucks or railcars should be washed from previous load to prevent mixing with leftover residuals or water. In cold weather can be shipped in several ways – Hot for immediate delivery ( F) – Hot ( F) in railcars for delivery within 7-8 days – Frozen in railcars equipped with steam coils – Blended with winter diesel, kerosene or other low cloud point fuel 64

Emissions Reductions with Biodiesel Blends Emission Type B100 B20 B2 Total Unburned Hydrocarbons -67%-20%-2.2% Carbon Monoxide -48%-12%-1.3% Particulate Matter -47%-12%-1.3% Oxides of Nitrogen (NO X ) +10%+ 2%***+0.2% “When considering the combined benefit of all these reductions, the small increase in nitrogen oxides (NOx) should not overshadow the net environmental gain with biodiesel use in North Carolina. Biodiesel is a viable part of the overall effort to improve our air quality.” B. Keith Overcash, PE, NC DE&NR, DAQ 65

The Future of Biodiesel Should be considered for use as an alternative and not a primary fuel Short and long term environmental benefits will be worthwhile Storage Issues with Stability and Transportation issues with high cost of delivered fuel compared to fossil fuels Fuel-supply reliability Lack of understanding of environmental impact - NOx emissions Complexity of biomass-power infrastructure compared to known well established coal and natural gas markets 66