Bio-diesel plant manufacturing in technical collaboration with Green Fuels Limited (UK, Germany).
Our bio-diesel system is an innovative technology which can use different kinds of fresh vegetable oils (e.g. sunflower, rape seed oil, palm oil) but also used vegetable oils and fats.
There is no need for any technological or process modification if another input material will be used.
The change from fresh vegetable oils to waste oils and vice versa can be done during normal operation; there is no need for a shutdown of the system. Only the software of the automatic process control has to be adjusted to the new input material.
The bio-diesel plant manufacturing system is able to use different cold- and hot pressed fresh vegetable oils as well as pre-treated used vegetable oils.
In all cases, if the operator of the plant follows the required qualities of the input materials and ensures a constant process operation, the product quality will be in correspondence with the requirements of the European bio-diesel standard DIN EN 14214 as well as with all other conventional international norms.
It has to be pointed out, that used vegetable oils and certain fresh oils like palm oil only can be used for the production of so-called “summerbiodiesel” because the winter stability can not be ensured yet. For all different raw materials a transesterification grade of > 98 % and constant product quality will be reached.
The system requires just low amounts of water (approx. 10 %). The produced soap water is fed into the glycerine phase. The control and monitoring system operates automatically due to the installed PLC-system.
The transesterification of the raw oil will be done by using the classical alkali-process. The catalyst solution will be prepared in a separate tank: Potassium hydroxide is fed from a big-bag into the reactor via dosing system.
Then methanol is added. The catalyst KOH (Potassium Hydroxide) will be prepared as approx. 12.5%- methanolic solution. Methanol, the catalyst solution and the input oil will then be mixed in the transesterification reactor. The precipitation and separation of the phases bio diesel and glycerine takes places via gravity in the following separation tank.
The glycerine phase will be discharged from bottom of the separation tank.
For removing the solved catalyst and the produced soaps the fatty acid methyl ester (FAME) has to be washed with water. Soaps are mainly responsible for the coking residue and have to be removed in accordance to the bio-diesel norm EN 14214.
Water is added to the raw bio-diesel by means of a static mixer. The separation of the mixture is done in a centrifuge due to the density differences of the substances.
The soap water is the heavier substance and can be separated from the FAME easily. The soap water is fed into the glycerine phase storage tank.
The bio-diesel is now heated up to 100-110 °C and is fed into the evaporation step. The evaporation operates under vacuum and at temperatures between 100 - 110° C. This operation process treats the products with care (avoidance of crack- and polymerization products) and saves energy-, service and operation costs.
In addition, surplus methanol evaporates from the raw-ester phase. The methanol is collected and returned into the process. To ensure the oxidation stability requested by the European norm (min. 6 hours), an antioxidant will be added to the final product.
To reach the requested CFPP-value (European Standard) during winter (19.10.-28./29.2.) if rape seed oil is used, an additive is added. Finally, the product bio-diesel is stored in tanks until its further use.
Process Control System
The process control system allows the automatic operation of the bio-diesel plant. The plant operators are just necessary for the supervision of the process, the product quality analysis and for maintenance and service. All electrical instruments and equipment in the production room are delivered in an xplosionproof design.
The complete system is designed in accordance with all necessary safety regulations.
Input Parameters and Requirements
For the quality of the fresh oil the German Pre-Norm DIN 51605 for pure rape seed oil fuel (based on Quality standard for pure rape seed oil used as vehicle fuel, developed by the Weihenstephan Institute 05/2005) shall be used as basis:
If used vegetable oils are chosen as input, they should be nearly free of animal fats and fish oil as well as other impurities like silicone. The used fats from frying purposes contain sunflower, rape seed, soy and olive oil in most cases. A 3%-FFA-content and a total content of impurities and water of max. 1% are feasible for the Continuous availability of fresh oil and/or used vegetable oil as raw material is required for a undisturbed and continuous operation of the plant (8.200 h/a).
The raw material has to be delivered in pumpable phase and must be free of impurities. Deviations of the required input parameter will lead to losses in quality and quantity of the produced bio-diesel. In addition, more catalyst and methanol might be necessary for the reaction as well as more washing water.
Advantages of the modular bio-diesel plant system being offered by Mectech