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Guide to Instrumentation for Biodiesel Fuel Production

INTRODUCTION
The gasoline engine was only six years old in 1892, when Rudolf Diesel developed and patented the first diesel engine as a more efficient power source. The diesel engine can be fed with vegetable oil and would help considerably in the development of agriculture of countries which use it, Diesel said when he introduced his invention to the world at the at the 1911 World Exhibition in Paris. But while Diesel did prove that pure vegetable oil can be an alternative to the petro-based diesel fuel, the viscosity was too high for practical use. Since that time, both the diesel engine and the biodiesel fuel production process have evolved considerably to minimize the viscosity problem, while the need for a fossil fuel alternative has been growing steadily. Biodiesel has become increasingly attractive as a non-toxic, biodegradable fossil fuel alternative that can be produced from renewal sources. In addition to peanut oil, which powered the first diesel engine, biodiesel can be produced from oils in soybeans, sunflower seeds, cotton seeds, rape seeds, palm, and even in some forms of algae. It can also be produced from used vegetable oils (cooking oils) and certain animal fats. The remaining hurdle is to get the cost of production low enough that it can also compete with gasoline, which will come as biodiesel producers improve and automate production operations. This paper contributes to that by describing the production process from the perspective of the measuring instruments that will be used to control operations. Processing out viscosity The following are among the production methods available to minimize the viscosity of vegetable oils, making them practical for use in internal combustion engines: Transesterification, also known as alcoholysis, which involves heating the oil with a catalyst and an alcohol to change its chemical structure Pyrolysis, also known as thermal cracking, which also involves heating the oil with a catalyst, but in the absence of air or oxygen. Micro-emulsification, which disperses the vegetable oil into a solvent such as methanol, ethanol, or butanol. Blending, which involves mixing vegetable oils with existing diesel fuel It is also well worth noting that maintaining ideal storage conditions through the entire product lifecycle is critical to standards compliance, quality, and cost-effectiveness of the biodiesel production process. Transesterification: Batch Transesterification is the most widely used method for commercial production of biodiesel. Transesterification, so named because biodiesel is chemically structured as an ester. Figure 1 depicts a typical batch reaction transesterification process. The oil is heated to a designated temperature, at which a catalyst, (often calcium hydroxide or sodium hydroxide) and an alcohol, often (methanol or ethanol) are mixed in. This results in the chemical reaction in which the triglyceride molecule from the alcohol neutralizes the free fatty acids and removes the glycerin, thus producing an alcohol ester. This separates the material into three layers, with the biodiesel on top, a soapy substance as the middle layer and glycerin on the bottom. fter some settlement time, the biodiesel must be washed to remove any soap, alcohol or impurities that may have entered the process. Washing is costly and time consuming, but must be done so the fuel meets ASTM D 6751 standards for biodiesel fuel. (Newly emerging computer-controlled continuous flow processes, eliminate the need for the washing cycle.

Basic Technology
Vegetable Oils Recycled Greases

Dilute Acid Esterification

Methanol + KOH

Transesterification

Methanol Recovery

Crude Glycerin

Crude Biodiesel

Glycerin Refining

Refining

Biodiesel Glycerin

Figure 1: Transesterification process

Extending processing time further is a period of drying to remove the water, and filtering to remove residual particulates. Additives, such as anti-Nox are added to the biodiesel, before it is ready for use. The soap and glycerin are drained off and pumped for additional refining for use in co-products. Temperature and pressure must be measured during transesterification and there, the relatively low 66 degrees C (150 degrees F) temperatures and 20psi pressures present minimal measurement challenge. Although there is still a need to measure levels, flow, temperature, pH and associated pressure. Transesterification: Continuous process Continuous process transesterification offers significant opportunities for efficient high volume production of biodiesel, including eliminating the costly washing and drying phases. A popular method uses continuous stirred tank reactors (CSTRs) in a series. The flexible process allows CSTRs with various volumes to be arranged in succession for optimum production. For instance, CSTR 1 may be a larger volume tank, which allows a longer residence time to achieve a greater extent of reaction. After the initial product glycerol is decanted, a faster reaction can take place in CSTR 2, with a 98+ percent completion. An essential element of the CSTR design is sufficient mixing input to ensure that the composition through the reactor is constant. As such, success is very dependent upon precise consistent measures of all process variables. Producing bio fuel through pyrolysis Pyrolysis is another method of reducing viscosity to make vegetable oils useable in internal combustion engines. In fast pyrolysis, shown in Figure 2, the oils are rapidly heated to 450 - 600 degrees C (842 1,112 degrees F) in absence of air. Heavy vibrations produced at this temperature break molecular bonds separating atoms at random positions, producing organic vapors, gases, and charcoal. The vapors condense into bio-oil. Typically, 70-75 % by weight of the feedstock is converted into oil in this way.

Ash

Flue Gas

10

Gas

R2
Sawdust 1 2 9 13

R1
5 9

C2

H1 C1
3

Air

P1

11 Oil

P3

P4

Air

P2

Figure 2

Pyrolysis has some very specific advantages. Because it is more of a physical than a chemical conversion, it enables de-coupling of process steps in time, place, and scale. The liquids used in the process are easier to handle and of more consistent quality than those used in transesterification, and the process itself produces a clean liquid, which requires no additional washing, drying, or filtering. Instrumentation requirements for pyrolysis are similar to those for transesterification, including temperature, pressure, level, flow and pH, although temperature and pressure measurement requirements will be much more demanding, given the 450 - 600 degrees C (842 1,112 degrees) temperatures and vacuum conditions that the process requires. Micro-Emulsification techniques Micro-emulsification, is the third method of controlling viscosity of biodiesel. The process involves dipping vegetable or other organic oils into solvents such as methanol, ethanol or butanol to disperse micro-emulsions (co-solvency). The micro-emulsion dispersions are transparent, thermodynamically stable and easily pass through fuel filters. Droplet diameters of micro-emulsions range from 100 to 1000 . A micro-emulsion can be made of vegetable oils with an ester and dispersant (co-solvent); or of vegetable oils, an alcohol and a surfactant, and a cetane improver, with or without diesel fuels. Water (from aqueous ethanol) may also be used for lowerproof ethanol, thus increasing water tolerance of the micro-emulsions. Blending biodiesel Although not necessarily suitable for large scale commercial application, viscosity problems in biodiesel can be managed through blending. Biodiesel be blended in any amount with petroleumbased diesel fuels, including Diesel #1, Diesel #2, or JP8. Where B100 is the name for pure biodiesel, B20 would be a fuel that contains only 20% biodiesel and B10 a fuel that contains only 10% biodiesel. B20 is a standard blend that meets the minimum requirements of the federal EPA Act clean air criteria. Based on todays diesel engine performance, B20 also is the highest recommended blend. Beyond a 20% blend has proven to be inefficient in diesel engines. Like any

petroleum based diesel fuel, biodiesel needs to blended with additives to keep it from gelling in extreme cold weather.

TYPICAL MEASUREMENTS IN A BIODIESEL PLANT

Regardless of which production process is used to produce biodiesel, raw materials, agents, products and co-products must be stored, pumped to various locations, and monitored and measured all the way. The following matrix provides a ready-reference guide to instrumentation suitable for biodiesel process measurements.

Typical measurements of bio-diesel production processes

Production Process Measurement Pressure Temperature Flow Analytical Level Invensys Foxboro Solution Models IAP10, IAP20, IGP10, IGP20, IDP10, IMV25 Transmitters Model RTT 15, RTT20 Model 83 Vortex, Vortex 84, CFT 50 Mass Flow, IMT25 / 9300 Magnetic Flowtube, IMV30 875 & 870IT pH & Conductivity Analyzers. IMV31 & IDP10 Transmitters, 144LVD & 244LVD Buoyancy Level Transmitter, Centeron Wireless Level Products

The Invensys Foxboro measurements and instruments product line With an installed base of field instrumentation in the biodiesel industry, Foxboro offers extensive expertise to provide on-target measurement solutions. And as the leading supplier of instrumentation for both dry and wet milling plants, Foxboro continues its tradition of Customer Driven Innovation. Founded in 1908 in Foxboro, Massachusetts, the company is credited with developing some of the original devices for making on-line, real-time measurement possible. Hallmark Foxboro innovations include pneumatic transmitters, the MagFlow magnetic flowmeter, pneumatic process gas chromatographs, and flow through conductivity sensors. Today, the company offers instrumentation for almost every stage of biodiesel production. These complement systems, software, and services to boost economic, safety, and environmental performance. The Foxboro measurement product line includes following product groups: Foxboro pressure transmitters Foxboro pressure transmitters combine field-proven, superior performance with application versatility, and rugged dependability. Available with a choice of electronic modules, and mounting configurations the product line includes the industrys most extensive offerings of multirange and multivariable instruments, as well as absolute, gauge, and differential pressure, and low power voltage output. Foxboro temperature transmitters Built for long term stability, Foxboro temperature sensors combine microprocessor-based technology to provide high reliability, maximum flexibility, and unmatched intelligence. Products support FOUNDATION Fieldbus, 4-20 mA, HART, or FoxCom Digital Output.

 Foxboro flow instrumentation From vortex and magnetic, to mass flow and digital Coriolis, Foxboro offers a full range of flow products for the accurate measurement of liquid, gas, or steam. Designed to meet even the most demanding applications and accommodate diverse communications protocols, instruments are available in 4-20 mA, HART, FoxCom and FOUNDATION Fieldbus. The product line includes sanitary 3A authorized flow products for food and beverage, dairy, pharmaceutical, and bio-tech applications. Foxboro electrochemical measurement technology Foxboro electrochemical technologies assist in analysis or control of pH, ORP, conductivity, resistivity, or dissolved oxygen. The line includes a broad range of robust, accurate, high quality liquid analytical instrumentation for industries including pharmaceutical, chemical, food and beverage, pulp and paper, metals, semiconductor, power generation, water and wastewater, and more. Foxboro level transmitters Foxboro level transmitters are durable, highly accurate instruments that provide premium performance. The product line includes advanced technologies to meet the varying demands of biodiesel level measurement, including the ability to detect the liquid phase change between the fuel and discarded materials. Foxboro multivariable technology compensates for density changes caused by pressure & temperature variations to provide accurate level measurement in either open (vented) or closed (pressurized) tanks, while Foxboro buoyancy level & density transmitters withstand the temperatures involved within the process. Foxboro also offers wireless level products that provide a cost effective alternative for selective applications. In addition to its products, the following Foxboro offerings support efficient bio-diesel production: Next day shipment In currently running plants, downtime can be expensive. In expansion or new constructions, staying on plan, on budget requires having parts there when they are needed. Sometimes long range planning is just not possible and a project could sit on hold waiting for instrument shipment for a critical part of the facility. To eliminate the process some instrument manufacturers are guaranteeing next day ship on certain transmitters. Training Foxboro M&I offers Customer designed training classes to supply knowledge in the areas of installation, configuration, operation, and trouble-shooting for all Products. These classes can be done on-site or at the factory, whichever meets the Customers convenience. Customer 24/7 support - Given the recent expansion of the biodiesel industry, a vendor that understands the needs of producers as well as the technology can be a significant source of cost savings in and of itself. Two innovations which would be particularly relevant to biodiesel producers are next day shipment of user defined instruments and 24/7 technical support.

CONCLUSION
As the US increasingly seeks domestic fuel alternatives to foreign oil, biodiesel is a very promising fuel alternative. The biodiesel fuel production process has evolved considerably to minimize the original problems with viscosity. Today, biodiesel is an increasingly attractive, non-toxic, biodegradable fossil fuel alternative that can be produced from a variety of renewable sources. The new challenge is getting the cost of biodiesel production low enough that it can compete with gasoline, which will come as biodiesel producers improve and automate production operations. Process measurements and instrumentation can be very valuable to ensure that product is produced safely, cost-effectively, and according to ASTM specifications. In addition to a solid price/performance value with instruments, biodiesel producers need ease of implementation, flexibility, scalability, low maintenance and support. These needs are being met with recent advances

in instrumentation technology. Furthermore, with on going improvements in design and materials, and methods of delivering technology and support, careful evaluation of instrumentation can reduce both equipment and operating costs significantly, while improving overall biodiesel production efficiency.

RESOURCES AND ACKNOWLEDGEMENTS National Biodiesel Board U S Department of Energy Willie Nelson Biofuels ATTRA BTG As. Ramadha, S Jayaraj, C. Muraleedharan. Use of vegetable oils as I.C. engine fuelsA review. Department of Mechanical Engineering, National Institute of Technology Calicut, Calicut REC P.O. Calicut 673601, India www.biodieselnow.com J. Van Gerpen, B. Shanks, and R. Pruszko; D. Clements; G. Knothe. Biodiesel Production Technology. National Renewable Energy Laboratory. August 2002-January 2004

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