Biodiesel Process Overview
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1 Biodiesel Process Overview 2/11/08 INSPECTION POINTS Purchasing Inventory Production Sales Shipping Customer Support Purchase Order List Checklist material dependent Inspection per material spec Inventory Feedstock Soybean Oil Catalyst Sodium Methylate Bulk Feedstock Step-01 Reactor Catalyst MWT Monomer Weigh Tank recovery Step-02 Water Demethylation Reactor-F or I Recovery Biodiesel Recovery Method Cut Tank I Reactor D Reactor Source Reactor or Holding Tank Step-03 Demethylation of Biodiesel Isolated Shipment Lot Biodiesel Step-04a Multiple Batches Acid Wash Step-04b Water Wash tag-out Step-05 Shipment Lot Inspect Dry Step-04c COA Shipping sample/test sales or scrap Batch Final Multiple Bulk Storage Tanks D6751 Page 1 of 5
2 References 1. Purchase Order Listing of Quality Records & Unloading Tanker Trucks Purchase Order Procedure & Unloading Railcars Purchase Order Form Shipping Product by Tanker or Railcar Purchase Order Procedure Bulk Checklist & Unloading Tanker Trucks Inventory Checklist for Bulk & Unloading Railcars Daily Report Log Railcar Checklist (Ship & Receive) 3. Inspection QA Lab Specification Transmittal Sheet (except shipment samples) Lab Spec Work Instruction for Providing Samples to QA Lab Spec Sodium Methoxide Lab Spec Soybean Oil 4. Step 01 - Reactor Batch Step 1-Biodiesel I Reactor Batch Step 1-Biodiesel H Reactor I Reactor Log Sheet H Reactor Log Sheet-Decanting System I Reactor Time Chart-Decanting System H Reactor Log Sheet- Tank I Reactor Down Time Chart-Decanting System H Reactor Time Chart- Tank I Reactor Log Sheet-Decanting System H Reactor Time Chart-Decanting System Biodiesel, I Reactor SOP H Reactor Down Time Chart-Decanting Sys Lab Spec- I Reactor (In-Process) H Reactor Down Time Chart- Drain Determination in Reactor Sample Biodiesel, H Reactor SOP Lab Spec Reactor (In-Process) H Reactor 5. Step Batch Step 2-Biodiesel, F Reactor K-F Water Determination Method F Reactor Log Sheet-Front Load Sulfuric Acid Lab Spec- F Reactor Demethylation of F Reactor Down Time Chart Batch Step 2-Biodiesel, I Reactor F Reactor Log Sheet-End Load Sulfuric Acid I Reactor Demethylation of SOP F Reactor Time Chart-End Load Sulfuric Acid Lab Spec- I Reactor Demethylation of F Reactor Demeth. Process-Front Load Sulfuric Acid F Reactor Time Chart-Front End Sulfuric Acid F Reactor Demeth. Process-End Load Sulfuric Acid F Reactor Down Time Chart-End Load Sulfuric Acid I Reactor Demeth. Of I Reactor Down Time Chart-Demeth. Of I Reactor Time Chart-Demeth of Page 2 of 5
3 References 6. Step 03 Demethylation of Biodiesel Lab Spec- D Reactor-Demeth. of Biodiesel I Reactor Demethylation Log Sheet Lab Spec Demethylation of Biodiesel Cut Tank Log Sheet Batch Step 3-Biodiesel Demethylation by Cut Tank Cut Tank Demethylation Procedure Batch Step 3-Biodiesel Demeth.- I Reactor Cut Tank Time Chart I Reactor Time Chart-Demethylation Cut Tank Down Time Chart D Reactor Log Sheet D Reactor Demeth. Time Chart D Reactor Demethylation Procedure Batch Step 3-Biodiesel Demeth.- D Reactor I Reactor Down Time Chart-Demethylation D Reactor Down Time Chart I Reactor Demethylation of Biodiesel SOP Batch Step 1-Biodiesel I Reactor I Reactor Log Sheet-Demeth. From Bulk Tanks I Reactor Time Chart-Demeth. From Bulk Tanks I Reactor Down Time Chart-Demeth. From Bulk Tanks 7. Step 04 Blend Tank Lab Spec Blend (In-Process) Isolation of Bulk Tanks Ready for Shipment Batch Step 4-Biodiesel Wash by Blend Tank Recovery of Biodiesel from Water Wash Batch Card Citric Acid Solution Biodiesel Single or Double Water Wash SOP Batch Card Biodiesel from Water Wash Blend Tank Log Sheet Blend Tank Time Chart Blend Tank Down Time Chart 8. Step 05 Shipment Lot QA Lab Specification Transmittal Sheet (except shipment samples) WI for Relative Density Determination Determining Significant Process Change WI for COA for Shipment of Biodiesel (D6751) Shipment Lot Tank Homogeneity Batch Step 5-Biodiesel Lot D6751 COA Work Instruction for Providing Samples to QA Isolation of Bulk Tanks Ready for Shipment 9. Shipment D Shipment & Billing of Finished Goods Procedure Lab-Ship Sample Test Open Sales Orders Form Shipping Product by Tanker or Railcar QA STS Definitions (for D6751 Shipment) Daily Shipping Report Log WI for COA for Shipment of Biodiesel (D6751) Pulling Samples from Tankers Loaded for WI for QA STS for Ship or Past 30 Days Sample Shipment Page 3 of 5
4 Document Approvals Role/Position (Normative) COO CTO Role/Position QA HSE Purchasing Shipping/ Owner: (informational) Bill McIlwain Terry Boone Reviewed By: Ravi Doshi John Roberts Peggy Davis Kenny Hawkins Approval Date Approved By: Document Control Jan Rector Instructions for filling out Document Approval Form 1. Identify the owner of the document who has technical authority for content. 2. Identify the authority required to review and approve (authority role). 3. Identify who acts within required authority for this release. 4. Approval date signifies that Document Control has received acceptance of approval. 5. Document Control has structural control as defined in Preparation & Release of Controlled Documents. Page 4 of 5
5 Date 10/31/06 12/7/06 1/12/07 3/27/07 2/11/08 Revision No Original issue Multiple clerical updates. Revision History Modification Reason Deleted tanks under Feedstock, added Tank 81; deleted tanks under Recovery and Biodiesel Recovery; updated doc. number for H Reactor BC; Deleted inspection checkpoint under. Add References per BQ-9000 Requirements, Rev. 4; deleted tank numbers & document numbers in flow chart. Added references for Step 1, 2,3 & 4; added D Reactor to flow chart. Page 5 of 5
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