Fully Automated Ethanol Fuel Distillation

EET 428 Senior Project

Michael Malski and Jason Wolniakowski

Abstract:

This project proposes building a fully automated fuel distillation machine that regulates
and controls the temperature and fluid levels; and can be used to make ethanol fuel for
vehicles. Every week gas prices keep rising with no real end in sight, and with this
machine it would be possible to save multiple dollars per gallon using the manufactured
fuel. The machine will be connected to a Programmable Logic Controller and the PLC
will then control the temperature and fluid levels allowing the production of any grade
ethanol fuel. In this project just under two gallons of E85 fuel will be produced, which is
a fuel composed of 85% ethanol made from five pounds of corn and 15% conventional
gasoline. The estimated cost for the two gallons will be $2.33. The project will be split
into five different stages. The first is the planning stage. The second, building the
distillation machine. The third stage is synchronizing the PLC to the distillation machine.
Stage four is testing and debug. Stage five is the presentation of the project. The project
will begin January 14, 2008 and will be completed by April 16, 2008. The budgeted cost
estimated for the project is $589.00.

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 Table of Contents

Cover/Abstract…………………………………………………………………………….1

Table of Contents………………………………………………………………………….2

Introduction………………………………………………………………………………..3

Project Architecture……………………………………………………..………………3-4

Specific Highlights…………………………………………………..………………….5-6

Operation……………………………………………………………………………….6-7

Testing/Changes…………………………………………………………………………..7

Resources………………………………………………………………………………….8

Going Further…………………………………………………….…..……………………8

Conclusions………………………………………………………………………………..8

References...….……………………………………………………………………...…….9

Work Breakdown Structure …………………………………………………..…………10

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Introduction

The main purpose of the project is to efficiently produce ethanol that can supplement or eventually
replace conventional gasoline.

As gasoline prices steadily rise consumers are beginning to look to forms of alternative energy.
According the Energy Information Administration summer gas prices are projected to be around $3.54 per
gallon. That figure is $.69 cents higher than last summers’ average price of $2.93. The EIA states that if the
average gasoline prices are around $3.54 per gallon this summer that it will most likely mean there will be
spikes where the price could go as high as $4.00. As seen in the chart below the average gas prices have
been increasing steadily over the last three years. 1

Despite the consistently increasing price per gallon of gasoline there is another fact to consider.
According to Petroleum Strategies.org in 2005 there were 1.2 billion barrels of proven oil reserves. In 2005
the world produced nearly 29.6 billion barrels of oil. At that given rate the world could run of oil in 40.6
years or 2045.If annual production also increases by 1% reserves could run out as early as 2037. Petroleum
Strategies.org concluded that even with increases in technology that it still may be possible to deplete all
reserves by 2100. 2

Planning Process

The project planning process included completing a project management class prior to
commencing work on the project itself. The class included learning the strategies of project management.
At the end of the semester a project planning report was written. Included in the report were many things
such as an overview of the project. The overview included the project abstract, assumptions, risks and
evolution of the plan. Also there were the managerial aspects, which included staffing, resource acquisition,
tracking and risk management. The Technical process plans section included a process model, methods,
infrastructure and acceptance. Finally there was a supporting process plans section, which included
verification, quality assurance and documentation. Included below is the Gantt chart outlining the timing of
the various stages of the project. It can be seen that the initial planning of the project was projected to last
three weeks. While the majority of the planning was done in this timeframe there was still much more
planning and research that was done concurrently with other stages of the project. A work breakdown
structure was also created in order to organize the tasks that were to be completed by each of the team

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members. The breakdown structure was designed to keep team members working on separate tasks in order
to maximize efficiency. The work breakdown structure can be found on page 10.

Project Architecture

Software

Software that was used in the project included RSLogix 5000, Boot DHCP Server, RS Linx, and
IP Config. RSLogix 5000 was used to write the program for the micro logic controller. Boot DHCP Server
was used to assign IP addresses to the programmable logic controller and the computer. RS Linx was the
program that provided the drivers for the logic controller and the computer to communicate. IP Config is a
Windows program that allows the user to clear the computer’s IP address or assign a new one using DHCP.

Hardware

Other electrical devices that were used for the project include three windshield washer pumps, two
solid-state relays with 3-32 volt input, 12-volt mechanical relay, 1100-watt deep fryer, fluid level sensor,
1000-watt dimmer switch, 800-watt inverter, 12-volt car battery and voltage comparator circuit.

Windshield Washer Pumps: Two windshield washer pumps were used to transport the corn mash from the
first storage tank to the second. From the second tank the low-grade alcohol is pumped to the deep fryer.
The third pump was used to circulate cold water through the distillation column in order to condense the
rising alcohol vapors.

Solid State Relays: The first solid-state relay was used to turn on the heating element in the deep fryer. The
relay is activated by an input triggered by the programmable logic controller. The second was used in
conjunction with the logic controller to turn on the battery charger.

Mechanical Relay: The mechanical relay’s use was to turn on the first two windshield washer pumps when
the fluid level sensor detected low fluid in the deep fryer.

Deep Fryer: The deep fryer or boiler was used to boil the low-grade alcohol, and send the vapors up the
column.

Fluid Level Sensor: The level sensor was installed to detect when the majority of the low-grade alcohol in
the boiler was vaporized. The sensor would send a signal to the Logic controller, which then would activate
the mechanical relay turning on the washer pumps.

Dimmer Switch: The dimmer switch was used in order to adjust the current going to the heating element of
the boiler.

Inverter: The inverter’s purpose is to change the 12-volt direct current from the batteries into 120-volt
alternating current, which is required by the heating element in the boiler.

Battery: The battery was used to provide power to the windshield washer pumps as well as the inverter to
power the deep fryer.

Voltage Comparator Circuit: The voltage comparator circuit was used to detect when the voltage in the
batteries dropped below ten volts. When the batteries reached this condition the circuit would send a signal

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to the logic controller energizing a solid-state relay that would activate a charger to begin charging the
battery while the distillation continued unperturbed.

Solution Strategy

Originally during the planning phase of the project the intention was to create a fifteen-gallon
batch of mash to be boiled and condensed into ethanol. The main problem with this aspect is that the scale
proved to be too large for a first attempt at distillation. The boiler would require being very large, and to be
practical would need to be powered by something other than electricity such as a wood or gas-burning
furnace. As a solution the project was scaled down to a five-gallon mash, and the wood or gas-burning
furnace was replaced with the deep fryer. Despite the smaller scale it is still possible to demonstrate the
concept.

Another aspect that was changed from the original project plan was the design of the boiler tank
itself. In the plans the boiler tank was designed to have the low-grade ethanol pumped all at once into the
boiler tank, then heated until all of the liquid was evaporated. Since the boiler tank was changed to be much
smaller and heated with electricity, changes in the distillation process were required. Rather than pump all
of the low-grade alcohol into the boiler all at once, the level sensor in the tank would only allow the very
bottom of the boiler to be filled with liquid at all times. The logic behind this decision was based on the fact
that it would make no real difference if the water boiled all at once or if it was boiled away a little at a time.

Specific Highlights

Level sensor

One of the key components of the project is the level sensor inside of the boiler tank. The sensor
itself was constructed out of two ¼ inch threaded rods that were inserted through the top of the boiler tank.
Nuts were screwed on the top and bottom of the boiler lid so as to allow the sensor to be adjustable. The
sensor functions by applying a voltage to one of the rods. When liquid completes the circuit between the
two rods current is allowed to flow out the opposite rod and trigger an input from the programmable logic
controller to stop pumping more liquid into the boiler tank. The key is the differential in the length of the
rods. One of the rods is offset longer than the other so as to ensure that the change in the fluid level can be
detected. Since the sensor conducts only if there is liquid completing the circuit, the program in the logic
controller uses a normally closed contact to always pump liquid into the boiler tank unless given an input
from the sensor. Pictured below is a diagram of the level sensor.

Voltage Comparator Circuit

Another key component of the project is the voltage comparator circuit. The comparator circuit
was implemented to detect when the battery voltage fell below 11-volts. This is significant because if the

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battery becomes completely discharged it can take much longer to bring it back to being fully charged.
Fully depleting an automotive battery can be harmful to the longevity of the battery. In this case when the
comparator circuit detects a low voltage situation a signal is sent back to the logic controller, which then
activates a charger to complete the rest of the distillation. The circuit was originally constructed with a
voltage divider that could be adjusted with a 100k potentiometer and a 5.6-volt zener diode. The reference
voltage was fed into the inverting input of a 741 operational amplifier. However after further testing of the
circuit it was discovered that despite the output of the amplifier being in a low state there was still a voltage
on the output. This problem was remedied by using a LM393 voltage comparator chip. The reason for
changing to that particular chip was that internally the output was an open collector transistor. When the
transistor wasn’t biased then the output would go straight to ground providing either a completely on or off
state. Below is a schematic of the comparator circuit. 3,4

Operation

The operation of the system is fairly straightforward. When the logic controller is switched into
run mode, the normally closed contact in the main program activates the windshield washer pumps. The
pumps move the liquid from the first five-gallon bucket, which is the one containing the corn mash. The
liquid portion of the mash or low-grade alcohol is pumped into the second bucket. From there the low grade
alcohol is sent to the boiler tank. When the level of the liquid makes continuity with the level sensor the
logic controller shuts off the pumps through a mechanical relay. After that, the heating element of the boiler
tank is activated. Next, the voltage comparator circuit checks to make sure that the battery voltage is above
11-volts. If it is not then the logic controller will activate a solid-state relay to turn on the battery charger. If
it is then the loop will begin once again after some of the liquid in the boiler has evaporated into steam. The
steam makes it way up the column and over to the condenser section. At this time the third windshield
washer pump will have been circulating cool water through the condenser section. When the vapors come
in contact with the cool pipe with circulating water the vapor returns to its liquid form and drips down to a
collection tank. Pictured below is a block diagram of the process.

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Formulas/Predictions

Formulas that were included in the project primarily dealt with the amount of power needed to
complete one five-gallon batch of ethanol. According to those calculations it was possible to determine
how many batteries that would be needed and the relative cost of producing two gallons of fuel from the
five-gallon batch. Included as well was the price breakdown based upon how much of the process could be
run off the batteries alone, and then also if someone wanted to include solar panels to produce the necessary
amount of power to charge the battery in a reasonable amount of time.

According to a small-scale test performed, twelve ounces of water took 22.6 minutes to evaporate.
Since twelve ounces took 22.6 minutes to evaporate then one gallon would take 240 minutes. Then
multiply 240 minutes by five gallons, which equals 1200 minutes. Divide 1200 minutes by sixty to get the
total time of twenty hours. The test was performed with 667 watts of power at 95 volts and seven amps.
Based upon the average price of electricity in Michigan per kilowatt-hour, if the process was run
completely on AC power the electricity cost would be $1.33. This prediction was based on the fact that if
the system was run for twenty hours at 667 watts (20 hours * 667 watts = 13.34 kilowatt-hours. The
average price per kilowatt-hour in Michigan is ten cents. Multiply ten cents times 13.34 kilowatt-hours (.10
* 13.34 kilowatt-hours = $1.33).

The battery’s life is based on amp hours, or the amount of hours the battery can run at one amp. In
this case a battery with a life of 500 amp hours would last 71.4 hours (500 amp hours / 7 amps = 71.4
hours). 71.4 hours would be sufficient to run the system for one batch, but the battery would be depleted, so
a second battery would be more practical for when the system needed to be charged. Only one battery was
used in this case to keep costs down, but one was enough to demonstrate the theory. 5

Given the scenario that a 140-watt, 8 amp solar panel were to be added, and the fact that Michigan
receives around four hours of good sunlight per day on average, the panel should be able to charge the
battery from an 80% depleted state in around 1.5-2 days.

According to professor Gary Todd, the cost for the five gallons of corn mash can be acquired at
the right time of year for around a dollar. Looking back at the calculations, given even the worst-case
scenario, where the system is run completely off of AC power, the cost of two gallons of ethanol would
then be $2.33.

Testing/Changes

One of the tests performed was voltage and current measurements on the boiler tank in order to be
able to calculate overall power consumptions. Similarly current draw testing was done on the windshield
washer pumps. The level sensor was tested to see if electricity would even conduct through water.

The voltage comparator circuit was also tested. The supply voltage was set at 11 volts. Then, the
potentiometer was varied until the output of the comparator circuit went high. In this manner it was
possible to create a set point for the process. During the testing of the comparator circuit was when it
became apparent that the 741 operational amplifier was not going to work for the project. As it was
discussed before the 741 operational amplifier always had voltage on the output even when it was supposed
to be off. At that time the LM393 comparator chip was used instead.

Another test that led to changes was when the level sensor was being tested. In the project the
level sensor was supposed to send a signal to the logic controller. Then the logic controller was supposed to
send a signal to a solid-state relay to turn on the windshield washer pumps. Everything worked on the test
except for the relay would not turn off once activated despite the fact that the logic controller was no longer
providing an input signal. This problem was remedied by using a mechanical relay instead.

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Resources

Project Cost

The majority of the project cost can be accounted for in the various copper fittings and pipes. The
total of those pieces came out to $140.00. The car battery would cost around $60.00. The windshield
washer pumps came out to be $30.00. The deep fryer used was purchased for $10.00. The level sensor
along with the wires, nuts and connectors came to $5.00. The three containers for holding liquid came to a
total of $15.00. If the solar system were to be added, that would increase the total substantially, but the total
cost of this project was around $260.00. If a second battery and solar panel (SX31045 140 watt 8 amp)
were added then the cost would increase to $1045.00. 6

Assuming a person pays for gas at least once every week. Given the current price of gasoline of
$3.45. Also assume that this system will be used to produce two gallons minimum for the week. The person
would then save $212.00 per year by not purchasing the gasoline. (($3.45 * 36 weeks)-($1.00 * 36 weeks)
= $212.00)). Even with the solar panel and extra battery the system would pay for itself in five years.

Human Resources

Project human resources came to a total of 183 man-hours. Included in the total is the work
performed by the group members as well as Professor Gary Todd and Steve Johnson.

Going Further

The most important thing that would make the project most viable is if the solar panels were
purchased. The key would be that the panels would provide enough power to run the system completely on
solar energy rather than charge the system with AC power. If this could be accomplished then the only
recurring cost would be the price of the corn mash. If this were the case then the ethanol produced would
then be created for less than a dollar using this system.

Another aspect that would make the project more viable is to create a larger batch so the output
per run would be higher. The important thing to consider is that if this system can create ethanol efficiently
then the scale can simply be increased and have the same effect.

If time permitted it would have been prudent to create more accurate temperature monitoring.
Currently with this system the temperature readings were measured, and the system was set at a point
where maximum efficiency was estimated to be. Since it was known that the low-grade alcohol boiled at
176 degrees Fahrenheit the power needed to run the system was set with the dimmer switch. Given more
time a more accurate way could have been implemented.

Conclusions

The main goal of the project was to create a system that was capable of efficiently producing E85
ethanol. In that aspect the goal of the project was completed because the system yielded close to two
gallons of ethanol at a cost of $2.33 even with the worst case scenario of running completely off AC power.
While the project was done at a relatively small scale, it would just be a matter of increasing the size for
more output. If solar panels were to be added then ethanol could be produced for just the cost of corn.
Given the current price of gasoline the system would pay for itself in five years or less.

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References
1
“EIA-Short Term Energy Outlook,”www.eia.doe.gov/emeu/steo/pub/contents.html, 2008.
2
“Are We Running Out of Gas and Oil,”
www.petrostrategies.org/learning%20center/Are_We_Running_Out_of_Oil and_Gas.htm, 2007.
3
“741 Op Amp Tutorial, Op Amps, Operational
Amplifier,”www.uoguelph.ca/~antoon/gadgets/741/741.html, 2007.
4
LM393 National Semiconductor product data sheet (DS005709), “LM393 Low Voltage, Low Offset
Voltage, Dual Comparators”, 2002.
5“
Charging the Lead Acid Battery”, www.batteryuniversity.com/partone-13.htm, 2007.
6
SX3140 BP Solar datasheet (6802.0012 v1), “140 watt Photovoltaic model”,
www.mrsolar.com/pdf/bp/bpsx3140.pdf, 2006.

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