Final Summary Report Development of a Safer, Code-Compliant, On-Campus System for Biodiesel Production SUNY Research Foundation Small Grant Sustainability Fund September 30, 2013 Dr. Benjamin D. Ballard Assistant Professor, Morrisville State College Duration of project: This project commenced on January 15, 2013, and continued through August 15, 2013. The biodiesel production operations and education will continue into the future. Amount of funds requested: $7,500 was requested from the SUNY Research Foundation Small Grant Sustainability Fund to undertake this project. Project participants: Dr. Benjamin Ballard, Assistant Professor of Renewable Energy and Director of the Renewable Energy Training Center (RETC) served as the principal investigator on this project. He was assisted by Mr. Seth Carsten, Instructional Support Assistant, and several students/summer interns: Hani Shayya, Logan Carsten, Steve Sgarlata and Sergei Domashenko. Project summary: Our initial plans for this project focused on the establishment of a campus-wide biodiesel cooperative and the addition of methanol recovery to existing operations. These plans were hindered following a fire inspection in February 2013. The inspection identified several important fire code issues relating to methanol handling and storage at our current biodiesel production facility, which resulted in the subsequent suspension of biodiesel production. As described in the revised project scope of work (revised 7/23/13), the primary limitations to the long-term operability of our current oncampus biodiesel production are several fire code-related issues, principally related to the storage, dispensing, mixing, and handling of methanol. These issues were addressed with support from the Small SUNY Sustainability Grant Fund, Morrisville Auxiliary Corporation, Morrisville State College (MSC) and the MSC Renewable Energy Training Center. There were two main tasks associated with this project, which will improve the long-term sustainability of the biodiesel operations and waste handling on campus. They included 1) the development of guidelines and procedures for the safe use of methanol in small-scale biodiesel production and 2) the modification of storage and handling systems for methanol at the Morrisville State College biodiesel production facility. The project produced two main deliverables: 1) A summary report (this document), which includes a summary of procedural changes implemented to address methanol/fire code issues, and an overview of the modifications/upgrades to the MSC biodiesel production facility. 2) A detailed how to guide for establishing an on-campus biodiesel production system. The guide provides practical considerations and recommendations for establishing and safely operating an on-campus biodiesel system. The guide discusses methanol storage and handling safety issues and provides a detailed list of the equipment, supplies/materials, and procedures used in the Morrisville State College Biodiesel Production Lab. Methanol handling and use guidelines and a model safety plan and are provided. These issues were addressed by modifying the lab space (e.g., methanol storage, ventilation, firewall, etc., detailed below) and constructing a sealed methanol dispensing system. We also developed a safety procedure manual, response Small SUNY Sustainability Grant: MSC Campus Biodiesel Project Final Report Page 1 of 5
plan, and training program for workers/students, which are all included in the Guide for Establishing and Operating an On-Campus Biodiesel Production System. We are currently (as of 9/30/2013) awaiting final electrical wiring of explosion-proof exhaust system, compressed air for the pneumatic methanol pump, and venting of flammables cabinets. Upon completion of these last items, the system will be re-inspected by the Fire Marshall, and we expect on-campus biodiesel production to resume this fall (2013). Included in this final report is a summary of the modifications to the MSC biodiesel production facility and a "how to" guide for setting up an on-campus biodiesel system, which we hope other campuses can use as a model. The "how to" guides includes our suggestions for addressing methanol/fire code issues, our safety procedure manual, safety response plan, and a guide for the physical setup for a biodiesel operation. Overview of procedural changes implemented to address methanol-related fire code issues Task 1: Research and develop guidelines and procedures for the safe use of methanol for small-scale biodiesel production. Develop a safety plan that specifically addresses methanol storage, handling and use for small-scale biodiesel production. Develop methanol handling manual and training guidelines for on-campus biodiesel production. Develop a how to (do it safely) guide for small-scale/on-campus biodiesel production. Accomplishments and Outcomes for Task 1: The Guide for Establishing and Operating an On-Campus Biodiesel Production System produced will provide the basis for biodiesel production operations at MSC. The guide will also provide necessary information for other SUNY campuses, institutions or community organizations to start (or resume) biodiesel production. The following materials were compiled and developed under the Small SUNY Sustainability grant and are included in the Guide : Introduction o An overview of the Biodiesel Facility and Renewable Energy at MSC Suggested Biodiesel Transesterification Procedures: o Free Fatty Acid Titration for Base Catalyst Determination o Test Batch Procedure o 27/3 Conversion Test Procedural Manual for Methanol Handling in a Biodiesel Production Facility o Procedural Manual for Methanol Handling o Worker training with sample test and answer key Morrisville State College Site-Specific Biodiesel Safety Plan (and MSDS) Building a Small-Scale Biodiesel Production System: Design and Process Specifications o Safety Considerations in a Small Biodiesel Production Facility (codes/regulations list) o System Overview and Equipment & Supplies Utilized for Biodiesel Production (detailed item and price lists) Small SUNY Sustainability Grant: MSC Campus Biodiesel Project Final Report Page 2 of 5
Overview of the modifications/upgrades to the MSC biodiesel production facility Task 2: Upgrade the current biodiesel production facility to meet fire codes and address safety issues related to methanol. Source/spec. the necessary equipment/materials/supplies for the upgrades and retrofits. Install/build the upgrades. Document the changes made, and make recommendations in the how to guide (see Task 1 and the accompanying guide ). Accomplishments and Outcomes for Task 2: The system upgrades to the MSC biodiesel production facility and the guidelines developed for safer, fire codecompliant biodiesel production (Task 1) will ensure continued future operation of the MSC system, converting campus WVO to renewable biofuel. A number of critical system updates were completed during the period of performance for the Small SUNY Sustainability Grant project (see Figures 1 and 2). Most of these updates are directly or indirectly related to fire code/safety issues associated with the storage and handling of methanol. The activities associated with the upgrades to the MSC biodiesel production system included the following: A closed methanol transfer system was designed, fabricated and installed, including a methoxide mixing vessel between the flammables cabinet and the BioPro 190 reactor (see Figure 2; contrast to Figure 1). Sheetrock seams on the wall partition in the biodiesel room were taped/sealed. A second layer of sheetrock was installed, taped, sealed and painted. The gap at the top of the wall partition was sealed at the ceiling with fire-rated foam. Two additional flammables cabinets were purchased (MSC campus $). A second corrosives cabinet was purchased to separate acids and bases (RETC $) Grounding for all flammables cabinets and the pallet rack was installed (MSC campus $ & labor). The plywood located under the flammables cabinet (and new methanol/methoxide tank) was replaced with metal grate (scrap salvage!), and an additional spill skid was purchased (MSC/MAC) and installed underneath. A pneumatic pump was purchased (MSC/MAC) and installed as part of the methanol transfer system (an air compressor and air dryer was purchased by MSC/MAC to run the pump). An explosion proof fan was purchased (MSC/MAC) and installed in the biodiesel production lab (awaiting final wiring, as of 9/30/2013). A combustible gas detector was purchased (MSC/MAC), which will be used in the biodiesel production lab. Additional safety supplies/ppe and biofuel testing apparatus were also purchased. Small SUNY Sustainability Grant: MSC Campus Biodiesel Project Final Report Page 3 of 5
Figure 1. Morrisville State College biodiesel production system configuration prior to the Small SUNY Sustainability grant updates to address fire code and general safety issues with methanol/methoxide storage and handling/transfer. Note the unfinished sheetrock wall and unsealed partition at ceiling (inset), lack of grounding, and open transfer of methanol (no closed system installed between methanol storage and processor). Figure 2. Updated biodiesel system configuration after the Small SUNY Sustainability grant updates to address fire code and general safety issues with methanol/methoxide storage and handling/transfer. Note the finished sheetrock (also added second layer) and sealed partition at ceiling (see inset, left), grounding (see inset, right), closed methanol transfer system installed (between flammables cabinet and BioPro 190), plywood removed, replaced with metal grate and additional spill skid installed under methanol/methoxide tank and flammables cabinet. Note that the exhaust pipe for the flammables cabinet has not yet been installed in this photo. Small SUNY Sustainability Grant: MSC Campus Biodiesel Project Final Report Page 4 of 5
Collective Project Outcomes and Future Plans: The system upgrades to the MSC biodiesel production facility and the guidelines developed for safer, fire codecompliant biodiesel production will ensure continued future operation of the MSC system, converting campus WVO to renewable biofuel. Through the efforts on this project, biodiesel sustainability has been improved by ensuring safe storage and handling of methanol, a key reagent in the biodiesel production process. MSC s on-campus biodiesel production operations will continue to provide students and staff with the opportunity to gain knowledge and practical experience with biofuel production and the benefits of renewable fuel. Waste vegetable oil (WVO) from on-campus dining halls will continue to be the primary biodiesel feedstock, reducing the cost of WVO disposal and providing a renewable liquid fuel for use in farm equipment at Morrisville State College s Equine Rehabilitation Center and greenhouse boiler system at the Aquaculture Center. Campus-produced biodiesel will provide an economic savings and environmental benefit to these campus operations by displacing petro-diesel. The Guide for Establishing and Operating an On-Campus Biodiesel Production System produced will provide the information necessary for other SUNY campuses, institutions or community organizations to start (or resume) biodiesel production. As we originally proposed, we plan to develop a biodiesel cooperative at Morrisville State College in the future. While we were not able to complete this during the allotted timeframe due to the unforeseen fire safety issues that were identified, and subsequently addressed, this project paves the way for future development of such a cooperative. It is our hope that the cooperative will then provide a model that may be replicated elsewhere. In addition to the aforementioned outcomes, four Renewable Energy Training Center interns/student employees were engaged in various aspects of the research, writing, design, and fabrication/construction necessary to complete the project. This enriched their employment/intern experience by providing a practical and hands-on learning experience. Small SUNY Sustainability Grant: MSC Campus Biodiesel Project Final Report Page 5 of 5