biodiesel india
TRANSCRIPT
BIODIESEL PRODUCTION TECHNOLOGY & FEEDSTOCKS FOR INDIA
PROF. NAVEEN KUMARCOORDINATOR, BIODIESEL RESEARCH
DELHI COLLEGE OF ENGINEERINGDELHI, INDIA
Email: [email protected] : 27871248, 32924637 Mobile : 9891963530, 981 0363530
UNIVERSITY OF MINNESOTA, OCTOBER 24,2006
Organized by
Moving Toward Sustainable Energy Systems: Exploring Global Pathways to a Common Destination
Expert Lecture at Workshop on
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 15607.
Glycerol
O O OMe Me Me
O = O =O =
HO
HO
HO
Biodiesel(Methyl Ester Alcohol)
3 ester alcohol + 1 glycerine
O = O OO = OO =
Triglyceride
1 triglyceride + 3 alcohol
3 MeOH
KOHCatalyst
catalyst
Transesterification Reaction
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.
Molecular Structure
Issues Related to Base Catalyzed Transesterification Process
� Feedstock IssuesFFAWater
� Process IssuesType of AlcoholMolar RatioCatalystReaction time & temperatureAgitation
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
2. WaterWater deactivates the catalysts. Drying of oil is required.Water hydrolyses fats to form free fatty acids.Free fatty acids react with alkali catalysts forms soapsSoaps semi solid mixture glycerol separation
Feedstock Issues
Process Issues
• 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.
Type of Alcohol
Catalyst?
“Chemical marriage brokers”The presence of a catalyst facilitates reactions that would be kinetically impossible or very slow without a catalyst
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
Various Catalysts used in Biodiesel Production
• 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
• Sulfated Zeolites & Clays• Hetro-poly acids• Metal Oxides, Sulfates• Composite materials
Homogenous
Heterogeneous
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.
Batch, Base Catalyzed Process
TG
Alcohol
Catalyst
Batch Reactor
Ester
Crude Glycerol
Alcohol
Alcohol
Wat
er
Water
Neutralized Glycerol
Wash Water
Dryer
Biodiesel
Water
Acid
Reaction Vessel
Heating Element
Water CooledCondenser
Cooling Water
10 Liters Biodiesel UnitStirrer
Development Cost : US $ 1300
600 LITERS/DAY BIODIESEL UNIT
Vacuum DrierSeparating VesselReaction Vessel
Washing Vessel
Control Panel
Oil Tank
MethaoxideVessel
Skid
Motor & Gear Box
Motor& Gear PumpDevelopment Cost : US $ 7000
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
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
1. Use acid catalysis for conversion of FFAs tomethyl 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.
Preferred method for High FFA feeds: Acid Preferred method for High FFA feeds: Acid Catalysis followed by base catalysisCatalysis followed by base catalysis
Methanol+
KOH
Vegetable OilStorage
Tank1500 Kg
Methanol +
H2SO4
Motor
StorageTank
500 Ltrs.
Motor
BiodieselStorage
Tank1000 Ltrs.
P2
SV2
Rea
ctor
600
Ltr
s.
SV2
AirSVO
P1
SV3
P3
Set
tling
Tan
k10
00 L
trs. Vaccum
Drier
Separating Column500 Ltrs./ Charge
Washing Column500 Ltrs./ Charge
Vaccum
Drier
Glycerol Storage Tank 500 Ltrs.
Transesterification Reactor, 500Lts./Charge
P4
P5P6P7P8
Biodiesel Unit1tpd Capacity
Design byDCE
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
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
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
AustraliaUsed frying Oil
Ireland , USABeef Tallow
JapanUsed Cooking Oil
NicaraguaJatropha Curcas Oil
GreeceCotton Seed Oil
SpainLinseed & Olive oil
PhilippinesCoconut
MalaysiaPalm Oil
U.S.A.Soya bean
EURape seed , Sunflower
CountriesFeedstock
Feed stocks used in different Countries
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
Target Output per HectareEstimated Biodiesel productionper 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 6.9 tonnesSeedcake 4.2 tonnesVegetable Oil 2.7 tonnesGlycerol 0.27 tonnes
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 $11mn for
nursery raising rest is expected to be sanctioned late this year� First 10,000 TPA plant in Hyderabad about to start production� Garware100,000 TPA DMT plant modified for biodiesel
production� A 250,000 TPA plant is being setup in Vishakhapatnam , A.P.� A 100,000 TPA plant is coming up in Kakinada , A.P.
India’s target of bio-diesel production
� 5 % mixing of Biodiesel in HSD by 2007� 20 % mixing of Biodiesel in HSD by 2012
Diesel & Biodiesel Demand, Area Required under Jatropha For Different Blending Rates
11.195.583.3513.386.693.3566.902011-12
8.764.382.1910.485.242.6252.332006-07
@ 20%
@ 10%
@5%
@ 20%
@ 10%
@5%
Area Requirement for Blending
(Mha)
Biodiesel requirement for blending (MMT)
Diesel Demand(MT)
Year
Summary
� Biodiesel is an renewable fuel for diesel engines that can be made from virtually any oil or fat feedstock.
� Biodiesel with a potential consumption of 15000 million litres can have a retail turnover of more than US$ 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.
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.