getting started in on-farm biodiesel production - attra · getting started in. on-farm biodiesel...
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Getting Started in On-Farm Biodiesel Production
By NCAT energy specialists Al Kurki and Rich Dana
A curriculum for agricultural producers
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
This webinar is being recorded and will be posted to the ATTRA Web site, www.attra.ncat.org.
Look for it here after Nov. 5, 2009. We will also post a PDF of the presentation.
www.attra.ncat.org
Rich Dana Al Kurki
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Overview• Introduction
• Advantages and disadvantages
• The chemistry of biodiesel
• Making your own biodiesel
• Small scale biodiesel production – processors
• Oilseed crushing
• Oilseed production
• On-farm examplesRapeseed. Photo by Marek Luty, courtesy of www.sxc.hu.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Introduction: what is biodiesel?
Photo by Howard Haines, MT DEQ.
• A permanently thinned vegetable oil
• A diesel fuel replacement or additive
• Biodiesel is NOT ethanol, straight vegetable oil (svo) or any mix of svo, gasoline or alcohol
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Advantages of biodiesel• Biodegradable
• Non-toxic
• Favorable energy balance – 4.5:1 for soy biodiesel
• Favorable emissions profile
Photo courtesy of USDA ARS.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Biodiesel reduces toxic emissions
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Advantages of biodiesel• Few or no engine modifications
• High cetane number and excellent lubricity.
• Very high flashpoint (>300°F), makes for safer handling and storage
• Relatively low tech to produce
Photo by Howard Haines, MT DEQ.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Disadvantages of biodiesel• Lower energy content
• Poor cold weather performance
• Stability concerns
• Diesel engine manufacturers warrant engines, NOT fuel
Photo by Rich Dana, NCAT.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
The chemistry of biodiesel: Terms
• Transesterification – conversion of “esters”- replaces glycerol with methanol
• Glycerol = Glycerin (glycerol is “pure” glycerin)
• kOH – Potassium Hydroxide (caustic soda, pottash)
• NaOH – Sodium Hydroxide (lye)
• Methoxide – the methanol/catalyst mixture
• Titration – Volumetric analysis – determine how much FFA is present and how much extra catalyst is required to drive the biodiesel reaction to completion
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
The chemistry of biodiesel
Photo by Steve Fugate.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
The chemistry of biodiesel• All fats and oils are made up primarily of triglycerides – free fatty acids
and 7-13 percent glycerol (alcohol)
• 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
+ 3 = 3 +
Fatty acid Glycerin Alcohol
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
The chemistry of biodiesel• Almost any vegetable oil or animal fat combined with methyl or ethyl
alcohol and a catalyst
• Virgin oil requires 5.5 GPL NaOH, 7GPL KOH
• Waste oil must be “titrated” to determine acidity
• One pound of glycerin created for every 10 pounds of biodiesel
• Must meet ASTM 6751 specifications to be sold commercially
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
The chemistry of biodiesel
kOH (potassium hydroxide)• Absorbs less water
• Dissolves more easily
• Glycerin remains liquid
• Less harmful to plants
• More “forgiving”
NaOH (sodium hydroxide)• Less expensive
• More readily available
• Less required
• Makes solid glycerin
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
http://attra.ncat.org/attra-pub/biodiesel.html
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
Safety first! Check with local regulations• NCAT webinar on biodiesel safety and permits
– Jan. 14, 2010
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
• Safety first
• No blender batches
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Mixing a small batch
Photo by Ericka Dana.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
VegetableOil
• Plan your project in advance
• Safety first!
• Comply with local regulations and ordinances
• Materials handling – are you efficient?
• Waste handling – Do you have a plan?
• Sustainability – economy, environment, community
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
ReactorVegetable
OilReactor
• “Batch” method as opposed to continuous processing
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
ReactorVegetable
OilReactor
catalyst
• Remember: Methoxide handling is the most dangerous step in the process
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Photo by Lee Honeycutt
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Reactor
ReactorReactor
• Full reaction in about an hour
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
ReactorBiodiesel
Glycerol• Compost
• Fertilizer
• Soapmaking
• Biodigester
• Feed
• Do you have a plan to deal with the excess methanol?
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
www.dickinson.edu/departments/sustainability/biodiesel.html
Small batch processing
Photos courtesy of Dickinson College.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
ReactorBiodiesel
ReactorWash Tank
water spray
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Reactor
ReactorWash Tank
water spray
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Photo by Steve Fugate.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Reactor
ReactorWash Tank
wash-water treatment
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Reactor
“Dry” fuel by re-circulating through a shower- head, or simply leaving in an open barrel in the sun.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing
Photo by Steve Fugate.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing equipmentCommercially available batch processors: $3,000 - $10,000
Homebiokits.com
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing equipmentCommercially available batch processors: $3,000 - $10,000
Homebiokits.com www.northerntool.com
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing equipmentHomemade processors: $200 - ?
Photo courtesy of www.girlmark.com.
“Girl Mark”- Maria Alovert,Originator of the Appleseed Processor
www.girlmark.com
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Pitfalls
• Making biodiesel can be:– Time consuming (Time is $$$)– Messy ( waste disposal, spills,
rodents, etc.)– Dangerous (fumes, chemical
burns, fire)– Environmentally hazardous (
ground water, vapors)– Problematic (taxes, regulations)
Photo courtesy of www.biodieselpictures.com.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Small batch processing keys to success
• Start small – keep your mistakes small
• Plan ahead – build for the future
• Do your research – technology is changing
• Keep a clean shop – less waste, less work
• Share the work, share the benefits
• Keep it safe and legal
Photos courtesy of Steve Fugate.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Oil processing
• Clean, dehulled oilseeds must be crushed to extract oil
– This can be done on-farm or at a crushing facility
– Small scale systems use mechanical crushing – cold press
• Before conversion to biodiesel,oil must be degummed:– Treat with phosphoric acid for
4-8 hours– Water wash
Photo by Howard Haines, Montana DEQ.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Farm-scale oil presses• Types of mechanical oil presses –
ram, single cylinder or cage
• Powered by an electric or diesel motor
• You get what you pay for in crushers
Photo by Amanda Lowe, NCAT.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
• Getting out the most oil in cold pressing
– Warm seed – Warm equipment – Run pressings through a second
time
• Go to www.ncat.org/special/oilseeds.php and www.attra.ncat.org/attra-pub/oil-seed.html
Oilseed presses
Photo courtesy Ken DeBoer.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
U.S. oil-producing crops
Land crop yields/acre based on US average 2008
Crop Avg Harvest (lbs) Oil Content % Avg Gal./Acre (approx.)Peanut 3,416 47 105Canola 1,461 43 59Sunflower 1,429 40 53Safflower 1,592 33 49Soybean 2,376 19 42Corn 8,618 4 32Camelina** 569 35 19Cottonseed 813 19 14
*Harvest yields from USDA NASS service, 2008 figures** Montana data only
Yield x pct.oil x crusher efficiency/7.5 = gallons of oil per acre
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Not all oilseeds are equal• Where does it grow – warm or cool climate
• Value for human consumption versus fuel
• Bioproducts other than fuel
• Oil properties readily suitable for biodiesel
Photos courtesy of USDA ARS.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Soy, sunf lower, canola, camelina• Soy — scores well on fatty acid levels,
viscosity, cold flow properties, stability and sulfur content
• Sunflower — good on viscosity and sulfur levels, lower on stability
• Canola — Superior cold flow properties, higher on sulfur, mid range on other factors
• Camelina — Superior on cold flow, mid range on fatty acids and viscosity, higher sulfur and unstable
Photo courtesy of USDA ARS.Source: Evaluation of Biodiesel from Camelina Sativa Oil, Nestor Soriano, MSU-Northern Bio-Energy Innovation and Testing Center, May 2008.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Keep in mind...• Feedstock (oil) is 80% of your
biodiesel cost if you buy it or grow it
• Equipment, oil, and methanol, catalyst and labor costs
• What are your goals?
• What’s your price point?
Photo by Amanda Lowe, NCAT.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Yoderville Biodiesel Collective• Kalona, IA
• Collect oil from over ten locations
• Hold weekly “brew nights”
• www.ybdc.org
Photos courtesy of Yoderville Biodiesel Collective.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Piedmont Biofuels
• Piedmont Biofuels is a worker- and member-owned cooperative
• Provide pure biodiesel (B100) to the community
• Maintain a top quality biodiesel plant where we make fuel from waste vegetable oil we collect locally
• Do education and outreach on behalf of biofuels
• Lobby the North Carolina legislature, as well as national representatives, on behalf of biodiesel and alternative fuels
• Have an intern program that allows people to learn about all facets of our operations.
• www.biofuels.coopwww.biofuels.coop
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Thad Doye sunflower biodiesel
• 2005-2007 crops and processing data
• $4.38/gallon for biodiesel in 45-gallon batches
• Change in labor rates and methanol recovery could reduce costs
Photo courtesy of Thad Doye.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Rocking Z Ranch / Zack Wirth• Wolf Creek, MT
• Uses biodiesel seasonally to operate tractors
• Wirth makes his biodiesel from waste vegetable oil
• $2.30 to $3.28 a gallon pre-tax biodiesel cost
• www.rockingz.com
Photo by Amanda Lowe, NCAT.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Rocking Z biodiesel costs 2008
Price comparison of Rocking Z biodiesel
Unit price This batchMethanol $3.43/gallon $60.37Catalyst $2/pound $20.04Oil $1.10/gallon $87.80
Total $168.01Biodiesel recovered 73 gallonsEfficiency 91%Cost per gallon No tax or power $2.30/gallon
Information from Rocking Z Ranch.
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
For more information• ATTRA biodiesel and oilseed processing publications at
www.attra.ncat.org/farm_energy/biodiesel.html
• Farmer stories at www.ncat.org/special/oilseed.php
• Small scale oilseed and biodiesel processing spreadsheets at www.ampc.montana.edu/energyinformation.html
• National Biodiesel Education Program at www.uiweb.uidaho.edu/bionergy
• Piedmont Biofuels at www.biofuels.coop
• National Biodiesel Board at www.biodiesel.org
The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)
Next ATTRA biodiesel webinars:
Safety and Permits, January 14, 2010
Taxation and Production Incentives, March 25, 2010
www.attra.ncat.org • [email protected]
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