1. BIODIESEL PRODUCTION TECHNOLOGY & FEEDSTOCKS FOR INDIA
Expert Lecture at Workshop on
Moving Toward Sustainable Energy Systems:
Exploring Global Pathways to a Common Destination
Organized by
UNIVERSITY OF MINNESOTA, OCTOBER 24,2006
PROF. NAVEEN KUMAR
COORDINATOR, BIODIESEL RESEARCH
DELHI COLLEGE OF ENGINEERING
DELHI, INDIA
Phone : , Mobile : ,

2. What is Biodiesel?
Biodiesel, a fuel composed of mono-alkyl esters of long chain fatty acids derived from variety of vegetable oils or animal fats, designated as B100, and confirming to different quality standards e.g. ASTM D 6751, EN14214 or IS

3. Transesterification Reaction
Triglyceride
1 triglyceride + 3 alcohol
3 MeOH
KOH Catalyst
catalyst
Glycerol O Me
O = HO
Biodiesel (Methyl Ester Alcohol)
3 ester alcohol + 1 glycerine

4. Molecular Structure
Fats and oils have quite big molecules with a spinal of glycerol on which are bond three fatty acid rests.
By the transesterification, the fatty acid rests are removed from the glycerol and each is bond with methanol.
The products are one mole glycerol and three mole of fatty acid methyl ester.

5. Issues Related to Base Catalyzed Transesterification Process
Feedstock Issues
FFA
Water
Process Issues
Type of Alcohol
Molar Ratio
Catalyst
Reaction time & temperature
Agitation

6. Feedstock Issues 1. Free Fatty Acids (FFA)
Free Fatty acids in the oils react with alkaline catalyst to form soaps.
R-OH + KOH K-OR + H2O
Acid + KOH Soap + water
It results in loss of catalyst and reduction in yield

7. Feedstock Issues 2. Water
Water deactivates the catalysts. Drying of oil is required.
Water hydrolyses fats to form free fatty acids.
Free fatty acids react with alkali catalysts forms soaps
Soaps semi solid mixture glycerol separation

8. Process Issues Methanol, Ethanol, Butanol etc
Type of Alcohol
Methanol, Ethanol, Butanol etc
Methanol –commercially used
In methanolysis, emulsion forms and separated into lower glycerol portion and upper ester portion. Reaction time is small
In ethanolysis, emulsions are stable and requires more complicated separation and purification process. Reaction time is large
Typical alcohol: TG ratio is 6:1 for base catalyzed reactions.

9. Catalyst? “Chemical marriage brokers”
The presence of a catalyst facilitates reactions that would be kinetically impossible or very slow without a catalyst

10. Homogeneous versus Heterogeneous
Homogenous
The catalyst, reactants and products are all in one phase, normally the liquid phase. The reactions proceed over a intermediate complex and are often highly selective, but separation of the products and the catalyst is difficult.
Hetrogenous
The catalyst is in one phase, normally solid, while the reactants and products are in another phase. Separation of catalyst and products is easy, but the reaction is often less selective, because the catalyst material is not homogeneous

11. Various Catalysts used in Biodiesel Production
Homogenous
Base Catalysts: NaOH, KOH, NaMeO
Acid Catalysts: H2SO4, PTSA, MSA, H3PO4, CaCO3
Typical base concentrations are :
NaOH/KOH – 0.3 to 1.5 %
Na MeO – 0.5 % or less
Heterogeneous
Sulfated Zeolites & Clays
Hetro-poly acids
Metal Oxides, Sulfates
Composite materials

12. Reaction time , Temperature & Agitation
Transesterification reaction will proceed at ambient (30°C) temperatures but needs 4-8 hours to reach completion.
Reaction time can be shortened to 2-4 hours at 40°C and 1-2 hours at 60°C.
Higher temperatures will decrease reaction times but require pressure vessels because methanol boils at 65°C.
Better agitation should be adopted to accelerate reaction.

13. Batch, Base Catalyzed Process
Alcohol
Water
Water TG
Ester
Biodiesel
Alcohol
Catalyst
Dryer
Alcohol
Wash Water
Water
Acid
Batch Reactor
Crude Glycerol
Neutralized Glycerol

14. 10 Liters Biodiesel Unit Development Cost : US $ 1300 Stirrer
Water Cooled
Condenser
Cooling Water
Reaction
Vessel
Heating Element
Development Cost : US $ 1300

15. 600 LITERS/DAY BIODIESEL UNIT
Control Panel
Motor & Gear Box
Skid
Oil Tank
Methaoxide
Vessel
Washing Vessel
Vacuum Drier
Separating Vessel
Reaction Vessel
Development Cost : US $ 7000
Motor& Gear Pump

16. High FFA Feed Stocks
Biodiesel feed stocks are classified by the amount of free fatty acids they contain:
Refined vegetable oils < 0.05%
Crude vegetable oil 0.5-5%
Used Cooking Oil 2-7%
Animal fat 10-30%
Price decreases as FFAs increase but processing cost also increase
Base Catalyzed Reaction not suitable for high FFA feeds because of soap formation.
Most of the non-edible oils available in India contains high FFA (2-12%) & to decrease the cost of biodiesel, it is imperative to utilize high FFA oil or fatty acids

17. Acid Catalyzed Processes
Acid catalyzed processes are used for direct esterification of free fatty acids in a high FFA feedstock
Limitations:
Water formation by
FFA + methanol ==> methyl ester + water
High alcohol: FFA ratio required – about 40:1
Large amounts (5 to 25 %) catalyst may be required

18. Preferred method for High FFA feeds: Acid Catalysis followed by base catalysis
Use acid catalysis for conversion of FFAs to
methyl esters, until FFA < 0.5%.
Acid esterification of FFA is fast (1 hour) but acid catalyzed transesterification is slow (2 days at 60°C).
2. Then, add additional methanol and base catalyst to transesterify the triglycerides.

19. Design by DCE Biodiesel Unit 1tpd Capacity
Air
SVO
Design by
DCE
Biodiesel Unit
1tpd Capacity
SV2 P1
Motor
Methanol +
H2SO4
Vegetable Oil
Storage Tank
1500 Kg
Reactor 600 Ltrs.
Settling Tank
1000 Ltrs.
Vaccum Drier
SV2 P3 P2
Motor
SV3
Methanol +
KOH
Storage
Tank
500 Ltrs.
Biodiesel
Storage
Tank
1000 Ltrs. P6 P8 P7
Vaccum
Drier P5
Transesterification Reactor, 500Lts./Charge P4
Glycerol Storage Tank Ltrs.
Washing Column
500 Ltrs./ Charge
Separating Column
500 Ltrs./ Charge

20. Barriers to Homogeneous Catalyst
Sensitivity to FFA & water content of the feedstocks
Removal of catalyst
Formation of soap with high FFA feedstock
Large quantity of effluent water as a result of removal of catalyst
Necessities pre-treatment of oil in case FFA content are higher
No scope for regeneration or re-utilization

21. Heterogeneous Catalyst

22. Benefits - Heterogeneous Catalyst
Catalyst Regeneration – Decrease of Catalyst Cost
Utilization of lower quality feed stocks for biodiesel production
Simplification of separation process – Decrease of production cost
Decrease of wastewater – Development of environmental friendly process

23. Product Quality
Product quality is important – modern diesel engines are very sensitive to fuel.
It is not biodiesel until it meets Quality Standards.
Reaction must be >98% complete.
Acid number – for degrading, oxidized fuel
Flashpoint – for residual methanol
Water & sediment – fuel fouling, deposits
Sulfated ash – for residual catalyst
Total glycerin – for incomplete conversion, detects residual mono, di and tri glycerides
Free glycerin – inadequate fuel washing

25. Feed Stocks for India

26. Feed stocks used in different Countries
Rape seed , Sunflower EU
Soya bean
U.S.A.
Palm Oil
Malaysia
Coconut
Philippines
Linseed & Olive oil
Spain
Cotton Seed Oil
Greece
Jatropha Curcas Oil
Nicaragua
Used Cooking Oil
Japan
Beef Tallow
Ireland , USA
Used frying Oil
Australia

27. WHY JATROPHA THE SUITABLE CHOICE ?
Thrives on any type of soil
Needs minimal inputs or management
Has no insect pests
Not browsed by cattle or sheep
Can survive long periods of drought
Propagation by seed/cutting is easy
Rapid growth
Yield from the 2nd year onwards
Yield from established plantations 5 tonne per ha.
30% oil from seeds by expelling
Seed meal excellent organic manure

28. Target Output per Hectare
Estimated Biodiesel production
per Hectare = 3,000 litres/700Gal
Potential yields of 12 tonnes per hectare and 55% oil Extraction are also attainable
2500 trees per hectare
produces
Seed tonnes
Seedcake tonnes
Vegetable Oil 2.7 tonnes
Glycerol tonnes

29. Anti-Erosive Properties
Reduces wind and water erosion of soil
Improved absorption of water by soil

30. Properties of press cake as fertilizer

31. Quality seedling preparation
10 x 20 cm bag
Germination -3 days
3-6 months old seedlings

32. VIEW OF JATROPHA PLANT NURSERY

34. Intercropping with Jatropha

35. Indian Biodiesel Program
Name of Biodiesel started making appearance at Indian Conferences, Workshops & Seminars in 1999
‘Report of the Committee on Development of Biofuel’ – Planning Commission, GOI in 2003
Stage I ‘Demonstration Project’ use Jatropha curcas on 400,000 ha (0.5 MMT BD) Nation-wide investment $ 300mn
Stage II – 11 mill ha (13 MMT biodiesel) for 20% blend.
Demonstration project started with initial grant of $11mn for nursery raising rest is expected to be sanctioned late this year
First 10,000 TPA plant in Hyderabad about to start production
Garware100,000 TPA DMT plant modified for biodiesel production
A 250,000 TPA plant is being setup in Vishakhapatnam , A.P.
A 100,000 TPA plant is coming up in Kakinada , A.P.

36. Biodiesel requirement for blending (MMT)
India’s target of bio-diesel production
5 % mixing of Biodiesel in HSD by 2007
20 % mixing of Biodiesel in HSD by 2012
Diesel & Biodiesel Demand, Area Required under Jatropha For Different Blending Rates
Year
Diesel Demand
(MT)
Biodiesel requirement for blending (MMT)
Area Requirement for Blending
(Mha) @ 5%
@ 10%
@ 20%
52.33
2.62
5.24
10.48
2.19
4.38
8.76
66.90
3.35
6.69
13.38
5.58
11.19

37. Land requirement for different blending percentages

38. Summary
Biodiesel is an renewable fuel for diesel engines that can be made from virtually any oil or fat feedstock.
Biodiesel with a potential consumption of million litres can have a retail turnover of more than US$ 9000 mn per year
It can provide huge rural employment potential of 40 to 50 million families and transform the rural economy
Remote village electrification and power for agriculture application – Energy grown & used by village.
The technology choice is a function of desired capacity, feedstock type and quality, alcohol recovery, and catalyst recovery.

39. Summary
The dominant factor in biodiesel production is the feedstock cost which around 70%, with capital cost contributing only about 7 % of the product cost. Therefore high FFA, lower quality feedstock should be promoted for biodiesel production in India.
For meeting energy security and electricity for all, it is necessary to develop and commission small to medium capacity biodiesel unit at village & community level..
Maintaining product quality is also essential for the growth of the biodiesel industry in India.

40. Thank You all for your precious time