Getting Started in On-Farm Biodiesel Production A curriculum for agricultural producers By NCAT energy specialists Al Kurki and Rich Dana
www.attra.ncat.org 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. Rich Dana Al Kurki
Overview Introduction Advantages and disadvantages The chemistry of biodiesel Making your own biodiesel Small scale biodiesel production processors Oilseed crushing Oilseed production On-farm examples Rapeseed. Photo by Marek Luty, courtesy of www.sxc.hu.
Introduction: what is biodiesel? 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 Photo by Howard Haines, MT DEQ.
Biodegradable Non-toxic Favorable energy balance 4.5:1 for soy biodiesel Favorable emissions profile Advantages of biodiesel Photo courtesy of USDA ARS.
Biodiesel reduces toxic emissions
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 Advantages of biodiesel Photo by Howard Haines, MT DEQ.
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 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 chemistry of biodiesel Photo by Steve Fugate.
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 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 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
Mixing a small batch Photo by Ericka Dana. http://attra.ncat.org/attra-pub/biodiesel.html
Mixing a small batch Photo by Ericka Dana. Safety first! Check with local regulations NCAT webinar on biodiesel safety and permits Jan. 14, 2010
Safety first No blender batches Mixing a small batch
Mixing a small batch Photo by Ericka Dana.
Mixing a small batch Photo by Ericka Dana.
Mixing a small batch Photo by Ericka Dana.
Mixing a small batch Photo by Ericka Dana.
Mixing a small batch Photo by Ericka Dana.
Mixing a small batch Photo by Ericka Dana.
Small batch processing Vegetable Oil 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
Small batch processing Batch method as opposed to continuous processing Vegetable Oil Reactor Reactor
Small batch processing Vegetable Oil Reactor Remember: Methoxide handling is the most dangerous step in the process catalyst
Small batch processing Photo by Lee Honeycutt
Small batch processing Full reaction in about an hour Reactor Reactor Reactor
Small batch processing Biodiesel Reactor Do you have a plan to deal with the excess methanol? Compost Fertilizer Soapmaking Biodigester Feed Glycerol
Small batch processing Photos courtesy of Dickinson College. www.dickinson.edu/departments/sustainability/biodiesel.html
Small batch processing water spray Reactor Biodiesel Reactor Wash Tank
Small batch processing water spray Reactor Wash Tank Reactor
Small batch processing Photo by Steve Fugate.
Small batch processing Reactor Wash Tank Reactor wash-water treatment
Small batch processing Dry fuel by re-circulating through a showerhead, or simply leaving in an open barrel in the sun. Reactor
Small batch processing Photo by Steve Fugate.
Small batch processing equipment Commercially available batch processors: $3,000 - $10,000 Homebiokits.com
Small batch processing equipment Commercially available batch processors: $3,000 - $10,000 Homebiokits.com www.northerntool.com
Small batch processing equipment Homemade processors: $200 -? Girl Mark - Maria Alovert, Originator of the Appleseed Processor www.girlmark.com Photo courtesy of www.girlmark.com.
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) Pitfalls Photo courtesy of www.biodieselpictures.com.
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.
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.
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 Farm-scale oil presses Photo by Amanda Lowe, NCAT.
Oilseed presses 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/oilseed.html Photo courtesy Ken DeBoer.
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 47 105 Canola 1,461 43 59 Sunflower 1,429 40 53 Safflower 1,592 33 49 Soybean 2,376 19 42 Corn 8,618 4 32 Camelina** 569 35 19 Cottonseed 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
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.
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 Source: Evaluation of Biodiesel from Camelina Sativa Oil, Nestor Soriano, MSU-Northern Bio-Energy Innovation and Testing Center, May 2008. Photo courtesy of USDA ARS.
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? Keep in mind... Photo by Amanda Lowe, 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.
Piedmont Biofuels Piedmont Biofuels is a workerand 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.coop
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.
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.
Rocking Z biodiesel costs 2008 Price comparison of Rocking Z biodiesel Unit price This batch Methanol $3.43/gallon $60.37 Catalyst $2/pound $20.04 Oil $1.10/gallon $87.80 Total $168.01 Biodiesel recovered 73 gallons Efficiency 91% Cost per gallon No tax or power $2.30/gallon Information from Rocking Z Ranch.
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
Contact us www.attra.ncat.org 1-800-346-9140 biodiesel@ncat.org Next ATTRA biodiesel webinars: Safety and Permits, January 14, 2010 Taxation and Production Incentives, March 25, 2010