METHANOL RECOVERY: BASICS, FINE TUNING, AND ENERGY BALANCE ISSUES. Dickinson College Biodiesel Shop Carlisle, PA

Transcription

1 METHANOL RECOVERY: BASICS, FINE TUNING, AND ENERGY BALANCE ISSUES Dickinson College Biodiesel Shop Carlisle, PA

2 What is methanol recovery? Biodiesel and Glycerin contain surplus methanol Methanol can be driven off via heating and captured for reuse May be done within biodiesel reactor or in standalone units Uses same procedures as making a batch

3 Why do methanol recovery? Removes toxic and flammable methanol from your biodiesel and glycerin Compliance with environmental laws Simplifies safe handling of fuel and byproducts Saves money and resources

4 How recovery works: methanol distillation basics Adding heat turns liquid methanol into methanol vapor (evaporation) Using water condenser cools vapors returning methanol to liquid state (condensation)

5 Plumber s Delight condenser

6 Booster condenser

7 Methanol recovery: how to do it

8 Methanol recovery: how to do it

9 Evaluating the purity of recovered methanol Biodiesel or Glycerin contains water in addition to surplus methanol Boiling point of water is 212 o F (100 o C) During recovery, fuel raised to above 240 o F Water vapors can potentially mix with methanol vapors Dilutes methanol during condensing stage

10 How to test the purity of recovered methanol

11 Running methanol recovery at the Dickinson shop

12 Methanol recovery road blocks Methanol recovery on glycerin Pro: glycerin is 30% methanol and yielded more methanol during recovery Con: increased amount of methanol overwhelmed 4 Plumber s delight condenser and produced greater amounts of wet methanol Alternative methods Booster condenser Re-circulated cooling Reflux column

13 Alternative methods: Booster Condenser

14 Alternative methods: re-circulated cooling

15 Alternative methods: reflux column

16 Basic reflux column design Item Quantity Price Total Price 2" to 3/4" Reducing Coupling " x 30" Black Steel Threaded Pipe Copper Scouring Pad /4" x 3/4" x 1/2" Reducing Tee /4" Nipple /2" MPT Dial Type Temperature Gauge & Well Total Cost:

17 Reflux column expectations Increased methanol purity Allow for successful methanol recovery with 5% pre-wash

18 Reflux column performance: methanol purity

19 Reflux column performance: methanol quantity

20 Reflux column performance: methanol content of glycerin Samples pulled at 240 o F, 250 o F, and 260 o F

21 Methanol Recovery Safety Biodiesel Contains 3-5% methanol Escapes into wash water Glycerol Crude glycerol contains about 25% methanol Classified as hazardous waste- toxic and ignitable Excess glycerol in the shop is a health and fire hazard. Plastic cubies of glycerol will leak with time Avoid stockpiling: have a plan!

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23 What is Energy Work is a force applied over a distance. W = F x D Energy enables work. Kinetic Energy Thermal Energy Potential Energy Mechanical Energy Electrical Energy

24 Watts, Joules, and BTUs 1 Joule / second = 1 Watt 3,600 Joules / Hour = 1 Watt 3,600 Joules = 1 Watt Hour 3,600,000 Joules = 1 Kilowatt Hour (kwh) Joules = 1 British Thermal Unit (BTU) BTUs = 1 kwh

25 150 Watts Kilowatts BTUs 2 hours = kwh Cost = 3 cents! 4, Watts Kilowatts 16,695.6 BTUs 2 hours = 9.79 kwh Cost = 99 cents!

26 Importance of a Balanced Shop Fuel Efficiency Input : Output Research Opportunities Cost Analysis Electrical, Material, Labor

27 Shop Equipment Item VoltAmps Wattage Tuthill Pumper Clear Water Pump Reactor Heating Component Dry Tank Heating Component Bubbler 4,50 1, ,

28 Material Input Input Cost Embedded Energy Gasoline $4.00/Gallon 125,000 BTUs Waste Vegetable Oil Free (For now) 0 BTUs New Methanol $4.10/Gallon 68,433 BTUs Recovered Methanol Free 0 BTUs Sodium Hydroxide (NaOH $2.43/Kilogram 11,247 BTUs Potassium Hydroxide (KOH) $8.44/Kilogram (not bought in bulk) BTUs

29 Embedded Energy Efficiency of Electric Energy Systems Friction/Deformation Energy/Thermal Energy Energy costs of making chemical components. Methanol Sodium Hydroxide Potassium Hydroxide

30 Saving on Energy Solar Energy q = m t cp q: Change in energy t: Change in temperature of the solution ( C or K) m: The mass of the solution (kg) Cp: Specific Heat Capacity (J/kg*K) q = 2.424kg 1.6 C J/kg*K q = 12,963J = 12.29BTUs

31 Saving on Energy Methanol Recovery Recovered methanol contains no embedded energy Production costs decrease for the next batch

32 Spread Sheet Microsoft Excel Worksheet

33 Back Up Plan! Processing Step Device VoltAmp Pf of Device Average Wattage Time (hours) Kilowatt hours BTU per kwh (energy used) Total energy (BTU) Pump Oil into Storage Tuthill , Pf x VoltAmp (.001) x time x wattage 3x BTU/kWh BTU x kwh

34 ELECTRICAL INPUTS A. Process step B. Device C. VoltAmp D. Pf of Devic e E. Average Wattage F. Time (hours) G. Kilowa tt hours (E X F X 1) J. BTU per kwh (energ y used) L. Total energy this step (BTU): (G x J) Pump Oil into Storage Pump II , Preheat Oil in Storage Solar Heating , Pump Oil into Appleseed Reactor Pump I , Preheat Oil in Reactor Reactor Heating Component 4, ,50 11, Mix Oil while Heating Pump I , Mix During Reaction Pump , Pump Glycerin out of Appleseed Reactor Pump I , Heat Fuel during Methanol Recovery Reactor Heating Component 4, ,50 11, Mix Fuel during Methanol Recovery Pump I , Pump Fuel into Settleing Tank Pump I , Pump Fuel into Wash Tank Pump I , Pump Fuel into Dry Tank Pump I , Bubble Dry Bubbler , Heat Dry Dry Tank Heating Component 1, , Mix Fuel while Drying Pump I , Total Time: Total kwh: Total BTUs:

35 Output:Input Analysis $ ,415,00 450, , #9 $ ,415,00 533, , #8 $ , , #7 $ ,415,00 420, , #6 $ ,415,00 367, , #5 $ ,415,00 702,82 879, #4 #3 #2 $ ,415,00 418, , #1 Cost Output:Input Ratio Total Output Electrical Input Material Input

36 $2.07 per Gallon Increase batch sizes Differentiate between recovered methanol and new methanol used in batched Buy materials in bulk

37 Considerations for the Future Better Record Keeping! Embedded Energy of Recovered Methanol Reflux Column for Methanol Recovery from Glycerin