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Biodiesel From Micro-algae. Group Delta Valerie Delligatti Dan Detro Kevin Jackson Joshua Jones Xin Qin. Project Mentor: Jerry Palmer. Current National Fuel Challenges. America has one-third of the world’s automobiles (230 million) and uses twenty-five percent of the world’s oil. - PowerPoint PPT Presentation
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Biodiesel From Micro-algae
Group Delta
Valerie Delligatti
Dan Detro
Kevin Jackson
Joshua Jones
Xin Qin
Project Mentor: Jerry Palmer
Current National Fuel Challenges
America has one-third of the world’s automobiles (230 million) and uses twenty-five percent of the world’s oil.
The Energy Information Administration projects thatreliance on foreign producers for oil will increase 30% through 2030.
Our transport sector’s greenhouse gas emissions will grow by nearly 40% through 2030.
Why Micro-algae?
One most important benefit of microalgae is its oil yield per land area.
Algae Strain Chlorella sp. (green
algae) Widely known Approximate
composition
Typically, 28 – 32 percent oil content by weight
45%
20%
20%
10%5%
ProteinFatCarb.FiberMin./Vit.
Design Basis
10,000 BPD of gasoline energy equivalency
10,567 BPD of biodiesel 10,450 BPD of Triglycerides
5,904 metric tons of algae/day
Algae assumed to be 28 wt % oil
Design Basis Increased levels of CO2 in ponds assumed
to cause a twelvefold increase in algal concentration.
Product concentration in pond 168 mg algae per liter broth (0.168 wt %).
Bumped up from a reported 14 mg per liter in 1000 m2 ponds 0.30 meters deep
Process Flow Sheet
Flue Gas Desulfurization Flue gas must be less than 20 ppm SO2
76 metric tons of flue gas per minute is required to provide a ~20% excess of algal CO2 requirements.
Flue enters FGD system at 200 ppm SO2 and leaves at ~2 ppm. SO2 removal rate of 0.9 metric tons per hour.
Algae Production
Photo-bioreactor
Pump (raceway pond)
De-gaser
Solar tube
Pump (solar tube)
Scrubbed Flue Gas
vent
Raceway Pond
Dirty Flue Gas
Paddle Wheel
Pump (FDSF) FDSF #1
Pump(storage tank)
Scrubber
Power Plant
Flue Gas Blower
Water/limestone
Water/limestone/SO2
Water/limestoneStorage Tank
Water/limestoneSO2 Storage
Tank
Pump (Scrubber)
Pump (Scrubber)
Tractor 1
To Extraction Unit
Nutrient Tank
Water/Nutrient
Nutrient to PBRNutrient to RWP
Flue Gas Out
Make up Water
Algae Production
CO2 used (metric ton/day)
NOX used (ton/day)
10801.6 40.94
Nutrient Requirement
Source mg/100 g Requirement for Process (short tons/day)Calcium 221 14.35Iodine 0.4 0.03Iron 130 8.44Magnesium 315 20.45Phosphorus 895 58.11Zinc 71 4.61Nitrogen 447.5 29.06
6494.6 short ton algae/day
Extraction
Extraction (GPM) (lb/hr)
Algae Input 1080.934806 541250
Water Input 22.05989401 11045.91837
Slurry Input 1102.9947 552295.9184
Algae Output 809.7498822 405461.2
Water Output 22.05989401 11045.91837
Oil Input 307.8762185 138560
Oil Output 301.7186941 135788.8
Oil retained in Algae 6.157524369 2771.2
Steam Input - 108342
S. Condensate Output 216.3706952 108342
Condensate Output 238.4305892 119387.9184
Slurry Input
Extraction SectionSteam Input
Algae Output
Oil Output
Condensate Output
25.6 % Oil in Algae by weight
2 % moisture in Algae by weight into Extractor
Extraction
Biodiesel Production
The Axens’ Esterfip-H process has significant advantages over the traditional process:
•Higher Yield•High Quality Glycerin
•98% Pure•No soap formation•100% Biodiesel yield
Biodiesel Production
Reactor 1 Reactor 2
Triglyceride feed(from Extraction Unit)
Partial Evap.
Settler Settler
Partial Evap.
Full Evap
Drier
condensor
Knock out Drum
Distillation column
Vaccum evaporator
condensor
Settler
Coalescer
Methanol Feed
Glycerin > 98%
Methyl Ester >99%
Biodiesel Production
Flow rate Inlet Outlet Inlet Outlet
(kg/h)reactor
1reactor 1 reactor 2 reactor 2
Methanol 62217 55747 62217 59729
Glycerin 0 5600 622 1867
Methyl ester 0 58858 57489 61595
Monoglycerides
0 2240 2240 995
Diglycerides 0 1244 1244 249
Oil 62217 747 622 0
Total 124435 124435 124435 124435
Temperature (C)
170-250 170-250
Pressure (atm)
30-70 30-70
Cost Analysis
Capital Cost $ Operational Cost $/yrEquipment + installation Maintenance + Service 20,729,451.98$ PBR - Nutrient 952,291.00$ Pumps 216,000.00$ ChemicalsExcavation 124,707,812.69$ CaCO3 2,047,650.00$ Reinforce concrete 29,186,972.70$ Make-up Water 13,790,216.45$ Asphalt 299,901,366.00$ PVC 57,469,581.20$ scrubber 175,000,000.00$ Algae Toaster 4,500,000.00$ Building 690,000.00$ Land 2,867,200.00$ Paddle Wheel 103,226,400.00$
Total 797,770,000.00$ Total 37,520,000.00$
Algae Production Unit Cost
Cost AnalysisCapital Cost $ Operational Cost $/yrEquipment + installation 24,000,000.00$ Maintenance + Service 720,000.00$ Storage 75,000.00$ ChemicalsChemicals Hexane (Make up) 665.75$ Hexane 133,149.00$ Mineral Oil (make up) 50.00$ Mineral Oil 16,240.00$
Total 24,210,000.00$ Total 730,000.00$
Capital Cost $ Operational Cost $/yrEquipment + installation 119,521,084.00$ Maintenance + Service 3,585,632.52$ Storage 500,000.00$ ChemicalsExcess Methanol (recycle) 10,651.62$ Methanol 15,710,900.78$
Total 120,040,000.00$ Total 19,300,000.00$
Exctration Unit cost
Biodiesel plant cost
Cost Analysis
Capital Cost $ Operational Cost $/yrCooling Tower 1,110,000.00$ Maintenance + Service 33,300.00$ Bolier 3,344,524.74$ Maintenance + Service 100,335.74$
Natural Gas & Water treat. 36,436,213.51$ Electric 50,722,609.45$ Labor 6,496,000.00$
Total 4,460,000.00$ Total 93,790,000.00$
$ $/yrTotal Capital Cost 946,500,000.00$ Total Operational Cost 151,400,000.00$
Other
Cost Analysis (Revenue)(Case 1) per yr
Biodiesel 443802 (gal/day) 3.47 ($/gal) 562,097,423.10$ Glycerol 342397 (lb/day) 0.5 ($/lb) 62,487,452.50$ Algae Cake 4413.935 (tonne/day) 30 ($/tonne) 48,332,588.25$ Carbon Credit 0 0 -$ N Ox Credit 0 0 -$ Total 673,000,000.00$
Revenue
(Case 2) per yrBiodiesel 443802 (gal/day) 3.47 ($/gal) 562,097,423.10$ Glycerol 342397 (lb/day) 0.5 ($/lb) 62,487,452.50$ Burn Algae Cake 53522 (MMBtu/day) 1.26 ($/MMBtu) 24,614,767.80$ Carbon Credit 0 0 -$ N Ox Credit 0 0 -$ Total 649,200,000.00$
Revenue
Revenue (Case 3) per yrBiodiesel 443802 (gal/day) 2.44 ($/gal) 395,250,061.20$ Glycerol 342397 (lb/day) 0.5 ($/lb) 62,487,452.50$ Burn Algae Cake 53522 (MMBtu/day) 1.26 ($/MMBtu) 24,614,767.80$ Carbon Credit 0 0 -$ N Ox Credit 0 0 -$ Total 482,400,000.00$
Cost Analysis (Payback)
IRR = 15%
Energy Analysis
Total energy used per day~20 million megajoules
Energy Analysis
Energy being produced by this process in the form of fuel is ~112 million megajoules per day.
Input to output ratio of ~ 1:5
ASTM biodiesel Standard
Plant Layout
References1. Chisti, Yusuf. "Biodiesel from microalgae." Biotechnology Advances 25
(2007): 294-306.2. National Biofuel Action Plant. Rep. Oct. 2008. U.S department of Energy.
Apr. 2009 <http://www1.eere.energy.gov/biomass/pdfs/nbap.pdf>. 3. Macleod, Claire S., Adam P. Harvey, Adam F. Lee, and Karen Wilson.
"Evaluation of the activity and stability of alkali-doped metal oxide catalysts." Chemical Engineering Journal 135 (2008): 63-70.
4. Gerpen, J. Van, B. Shanks, R. Pruszko, D. Clements, and G. Knothe. Biodiesel Production Technology. Tech. Golden: NREL, 2004.
5. Energy content of BioDiesel: http://www.biodiesel.org/pdf_files/fuelfactsheets/BTU_Content_Final_Oct2005.pdf
6. Molina, E., J. Fernandez, F. G. Acien, and Y. Christi. "Tubular photobioreactor design for algal cultures." Journal of Biotechnology 92 (2001): 113-31.
7. Aresta, Michele, Angela Dibenedetto, and Grazia Barberio. "Utilization of macro-algae for enhanced CO2 fixation and biofuels production: Development of a computing software for an LCA study." Fuel Processing Technology 86 (2005): 1679-693.
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