Integrated solar-biomass technology for production of green power and products

Chris Leech, Cody Cleaver, Ahmad Majzoub, Warren Furnival, Helen Lockhart

University of Western OntarioDepartment of Chemical and Biochemical EngineeringCBE 4497 Plant Process and Design

PFD Section 300 - Biodiesel Production

P-103 A/B

S-302

ST-301 ST-302

MX-301

ESTER-301

ESTER-302

HX-301

0.1

S-308

0.1ES/Out S-311 CENT-301

HX-302

HX-303

0.4

S-316

REMEOH

METHANOL

S-303

CATALYST WZA

S-304

SEP1-TOP S-313

SEP1-BOT

RCU-301

0.1

S-342

GLY-H20

CENT-302

WASTE ST-305

FATTYM

GLY-H20 HX-306

CD-303

GLY-H20

0.4

S-356

HX-307

0.4

S-349

CENT-303

HX-312

VDRYER-301S-337

OIL TRUCK-305

HX-3100.1

S-364

0.1S-312

VAP ST-301

S-338

0.1

S-340

HX-304

CD-301

HX-305

CD-302

GS-301/3

0.1

S-322

MX-302

0.4

S-343

Dist-301

0.1

S-323

0.1

S-320

0.1

0.1

S-321

0.1

0.4

SEP-302

0.4

S-353

S-354

0.4

S-3510.4S-352

0.1

S-335

S-336

MBTE Storage Tank

P-301S-306

0.1

S-319

DCV-301

P-302

P-303

S-362

P-301S-314

S-3410.1

PV-304

0.1S-324 S-325

Section 300- Transesterification

0.4 307

0.1S-344

S-345

P-304

S-348

SP-301

SP-302

SP-303

0.1

S-363

P-303

Oil from Extraction Section

Mem-301

0.4

S-310

Fatty Storage-301

0.1

S-309

FD-301

S-329

0.1

S-330

S-327

0.1

S-328

S-326

CSTR-301

S-357GLYCERIN

MX-303

S-355

M-304

0.1

S-332

Vacuum Flash-301

S-339

S-358

0.1

S-360

0.1

S-361

0.4

S-350

S-346

S-347

S-333S-334

S-301

S-307

0.4

S-305

333

0.1

S-318

S-331

0.1 298

0.2

0.1 0.1

0.1

0.1

0.1 0.1

0.1

0.1

0.1

0.20.1

0.1

0.1

0.1

0.1

0.1

0.1

0.10.4

0.1

1.72

298

298 298

298

298 298

320

300

380

350

298

2980.4

333

300

298

298

370

298

298

318

298

298

318

370

318

370

306

333

298

298

298

298

298

298298 333

333

333

330

370

298

298

298

298

330

298298

298

298

370

289

330

306

0.4 306

300

0.1 300

S-315

298

298

298

S-317

CW ST-308

S-364S-365

MV-301

0.1

298

Transesterification

FAME

Glycerol

WVO

Methanol

Innovation of Biodiesel Production

Glycerol-based fuel additive assists Decreasing in particulate emissions Act as cold-flow improvers Viscosity reducer

CSTR

C57H104O6 + 3CH3OH ↔ 3C19H36O2 + C3H5(OH)3 Total Volumetric Flowrate = 18,500 L/day

Residence time= 2.2 hrs

CSTR practical issues, key design considerations/challenges

Potential Problems Problem with high viscosity in algal oil when being

treated Formation of acrolein

highly toxic substance formed by thermal decomposition of Glycerol

Glycerol-based fuel additive increases biodiesel quality/commercial value Substrate used is Isobutylene Etherification is the transformation

process Catalyst used: Amberlyst-15

Benefits

Environmental Assessment Minimizing environmental impact of

waste streams

Only one waste stream: waste water

Our methanol is fully recycled and reused

Glycerol utilized as fuel additive instead of waste stream

Alternative CSTRs considered

CSTR vs Batch Reactor Utilizing methanol vs ethanol as alcohol Membrane vs Centrifuge

Catalyst

Acid

AlkalineEnzyme

Not influenced by FFA

Saponification

Not used commercially Sensitivity to purity of reactants

Research

Slower reaction

CSTR assumptionsAssumptions97% conversion is achievedRecycled vent gasses are mostly methanol

Reference temp.= 25 oC (298.15K)Cp values calculated with empirical formulas

2:1 height to diameter ratioPlant height restriction at 5 m

Detailed Design Calculations H:D ratio is 2:1, or R = 2

Where V is the volume (m3), and the height H is given by:

Detailed Design Calculations The power requirement [W] :

Therefore, the number of impellers (Ni ,rpm) was found using the correlation given in Haynes (2004):

Where k2 is the proportionality constant, ρ is the average fluid density, and Di is the impeller diameter.

CSTR Reactor CAD Design

CSTR sketch/dimensions/internals

Volume of reactor = 12.6 m3

Conical shape for bottom of reactor volume =0.5 m3 ,height = 0.5 m and diameter

= 2 mUnit Cost: $59,800Width of baffle: 0.09 mType of Impeller: Rushton TurbineBaffles: Carbon Steel Type 405Blades: Carbon Steel Type 410Material: Austenitic Stainless Steel (IS: 1570-

1961)Wall thickness: 135.91 mm

Process and Instrumentation Design

Simple Feedback Top Control

Flow controller for Algal Oil/Methanol/WZA volumetric flow

Level Controller utilized to prevent overflow

Temperature Transmitter maintains temp. at 65C

Supervisory Process Control allows all units to relay information to Process Logic Controller

Pneumatic valves set up for temp. and pressure regulation

Innovation in Biodiesel Production

Glycerol-based fuel additive assists Decreasing in particulate emissions Act as cold-flow improvers Viscosity reducer

Commercial Value for: Biodiesel reformulation Octane booster Decrease cloud point of diesel fuel

when blend with biodiesel

Economic Analysis

Total Equipment Cost

$13,162,500

Total Capital Investment

$11,210,000

ProfitabilityPrice $/tonne Price USD

FAME 868.21 7,000,000Glycerol 680.00 710,000

Tax Exemptions

200.35 1,603,000

Annual Sales Revenue

$9,250,000

Price $/gallons

FAME 2.95Glycerol

Profitability

ExpensesDirect 5,690,000Indirect 443,000General 1,030,000Annual Total Expense $7,160,000

Annual Net Income 2,080,000

Payback Period 5.4 years

Return on Investment 18.6%