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Biodiesel production plants
GENERAL INFORMATION
CONTENT
1. Introduction
1.1. Types of Biodiesel production units
2. Project development and project management
2.1. The plant2.2. Additional buildings2.3. Infrastructure
2.4. Used raw materials2.5. Agriculture area
3. Checklist for Biodiesel production
3.1. Production diagram3.2. Vegetable oils yields and ester characteristics3.3. International Biodiesel standard
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1. Introduction
Biodiesel is commonly made of rapeseed or soybean oil as primary, and methanol assecondary raw material. Befa offers beside this also a production way with ethanolinstead of methanol, and the know-how for many different primary raw materials as well.
Chemically, transesterified biodiesel comprises a mix of mono-alkyl esters of long chainfatty acids. The most common form uses methanol to produce methyl esters as it is the
cheapest alcohol available, though ethanol can be used to produce an ethyl esterbiodiesel. A byproduct of the transesterification process is the production of glycerin. Alipid transesterification production process is used to convert the base oil to the desiredesters. Any Free fatty acids (FFAs) in the base oil are either converted to soap andremoved from the process, or they are esterified (yielding more biodiesel) using an acidiccatalyst. After this processing, unlike straight vegetable oil, biodiesel has combustion
properties very similar to those of petroleum diesel,and can replace it in most current uses.A variety of oils can be used to produce biodiesel.These include:
Virgin oil feedstock; rapeseed and soybean oils are
most commonly used, though other crops such asmustard, palm oil, hemp, jatropha, and even algaeshow promise
Waste vegetable oil (WVO);
Animal fats including tallow, lard, yellow grease andas a byproduct from the production of Omega-3 fattyacids from fish oil.
Biodiesel feedstock plants utilize photosynthesis toconvert solar energy into chemical energy. The stored
chemical energy is released when it is burned,therefore plants can offer a sustainable oil source for biodiesel production. Most of the
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carbon dioxide emitted when burning biodiesel is simply recycling that which wasabsorbed during plant growth, so the net production of greenhouse gases is small andthat of CO2is zero.
We have a wide range of Biodiesel production plants, starting and using oil seeds, crudeoil and fats. We also offer the complete infrastructure to produce oil from seeds and fats.
1.1. Types of Biodiesel production units
type designation capacity: liters / day (24 hours)
SBDU-LIN: Small BioDiesel Unit Low Investment Line
Befa-SBDU-1200-LIN 1.200
Befa-SBDU-4800-LIN 4.800Befa SBDU-12000-LIN 12.000
Befa-SBDU-24000-LIN 24.000
SBDU-LEC: Small BioDiesel Unit Low Energy Consumption Line
Befa-SBDU-1000-LEC 1.000
Befa-SBDU-1600-LEC 1.600
Befa-SBDU-3000-LEC 3.000
Befa-SBDU-5000-LEC 5.000
Befa-SBDU-8000-LEC 8.000
Befa-SBDU-16000-LEC 16.000
Befa-SBDU-32000-LEC 32.000
MBDU: Medium BioDiesel Unit
Befa-MBDU-32000 32.000 (12.000 tons/year)Befa-MBDU-72000 72.000 (72.000 tons/year)
LBDU: Large BioDiesel Unit
Individual constructions with capacities from 40.000 to 500.000 tons/year
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2. Project development and project management
The whole project engineering will be done by BEFA. On all accounts BEFA needs two to
four locally persons for project development.If the project starts, BEFA and their project partners will accomplish a pre-study on thebasic information, which will be given by the authorities in the country. This pre-studywill covert costs and will allow making a first statement if the project is feasible.
After this pre-study, a full feasibility study will accrue.
This feasibility study will costs about 1,5 to 2,5% of the investment costs of the Biodieselproduction plant. The costs of the feasibility study are included in the contract with thegeneral planner.
Results of a feasibility study in Austria: first layout of a Biodiesel-plant
2.1. The plant
The plant will consist of several units:
o Storage for raw materialStorage tanks for oils and fats, capacity 6 weeks.
o Storage for finished productsStorage tanks for biodiesel, capacity 6 weeks.
o Energy-production plantOwn building for production of thermal energy for the whole Biodiesel-plant andsteam for heating the processes.
o Pre-treatmentBuilding for the pre-treatment for oils and fats to make them useable for thefollowing Biodiesel-production.
o Biodiesel-productionProduction hall for the Biodiesel production.
o Environmental installationsBuilding for waste water treatment, methanol/ethanol recovery and catalyst-recovery.
o Office and administrational building
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2.2 Additional buildings (not included in the standard concept)
o Oil mill and extraction deviceo Combined heat and power generation plant
2.3. Infrastructure (for a plant for 100.000 tons Biodiesel production per year):
o AreaA 100.000 ton-plant needs about 30.000 to 40.000 m free space.
Additional area if an oil mill and extraction has to be build.
o EnergyThe plant can be equipped with a power plant, which produces the needed thermal andelectrical energy with a surplus on energy. So the plant is energy self-sufficient!
oTransporting systems
The production plant needs a connection to streets and to the railway system if possible.
2.4. Used raw materials
The feedstocks for the biodiesel-production are:
o Animal fat, such as:beef / tallow fat, lard fat, mutton fat
o Vegetable oil, such as:rapeseed oil, soybean oil, sunflower oil, palm oil, cotton seed oil, jatropha oiland any other oils and fats.
o Secondary raw materialsMethanol or ethanol
o Amount of raw materials (for 100.000 tons Biodiesel):Fat and oil: 120.000 tons
Methanol: 12.500 tons or
Ethanol: 17.700 tons
The catalyst will be recovered in the process, losses are about 3 to 5%, this losses arenot so big amounts.
2.5. Agriculture area
If the required raw material is vegetable oil, BEFA can support project development andproject management for cultivation of oil seeds.
For an ecological and therefore profit-yielding harvest of oil seeds and vegetable oil thecrop rotation is very important and can be developed by BEFA.
This crop-rotation allows reducing the required land from 400.000 to 250.000 hectare for100.000 tons of Biodiesel-production a year.
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Ideal plant for land reclamation oil yield up to 1.600 kg per hectare (rape: 1.000, sunflower: 800 kg) subsided by Weltbank / World Bank IDEAL for Africa, reference projects in India OPEN QUESTIONS:
o cultivation time (months/years not) not available yeto available numbers of seedlings (?)o time to first harvesting and oil productiono TOXIC plant and press cake, IMPOSSIBLE for animal feedo BUT: press cake can be used for energy production
Depending on animal fat/oil:
butchered animals per year fat content of animals all animal fats and oils possible (beef/mutton/lard) extraction of oil from animal bodies and animal waste (building, plant, etc.) transporting system, etc. see rape seed
Biodiesel production plant
turn key plant 40.000m free area rail system / truck loading ports available infrastructure, energy production will be built. 40 to 50 employees, 5 to 10 SKILLED workers 2 3 technician / experts remain in Africa while plant operating
Ethanol production
Ethanol production, required 17.500 tons per year = 21.875 m / 21,875 mill litreo 96% ethanol naturally processing to 100% needs separate plant
fermentation of corn, maize, etc. turn key plantsin Europe available crop rotation with oil seeds will have ecological benefits
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3.1. Production diagram for multifeed stock
Rapseed Soy plants Sunflower Fallow land
Oil mill, ExtractionFirst treatment
Oil seedcake
Treatment plant Animal fat
Palm oil,
other
By-
roducts
Intermediateroduct
Biodiesel productionplant
Methanol orEthanol
Biodiesel
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3.2. Vegetable oil yields
Note: These are conservative estimates -- crop yields can vary widely.
Ascending order
Crop kg oil/halitresoil/ha
lbsoil/acre
USgal/acre
corn (maize) 145 172 129 18
cashew nut 148 176 132 19
oats 183 217 163 23
lupine 195 232 175 25
kenaf 230 273 205 29
calendula 256 305 229 33
cotton 273 325 244 35
hemp 305 363 272 39
soybean 375 446 335 48
coffee 386 459 345 49
linseed (flax) 402 478 359 51
hazelnuts 405 482 362 51
euphorbia 440 524 393 56
pumpkin seed 449 534 401 57
coriander 450 536 402 57
mustard seed 481 572 430 61
camelina 490 583 438 62
sesame 585 696 522 74
safflower 655 779 585 83
rice 696 828 622 88
tung oil tree 790 940 705 100
sunflowers 800 952 714 102
cocoa (cacao) 863 1026 771 110
peanuts 890 1059 795 113
opium poppy 978 1163 873 124
rapeseed 1000 1190 893 127
olives 1019 1212 910 129
castor beans 1188 1413 1061 151
pecan nuts 1505 1791 1344 191
jojoba 1528 1818 1365 194
jatropha 1590 1892 1420 202
macadamia nuts 1887 2246 1685 240
brazil nuts 2010 2392 1795 255
avocado 2217 2638 1980 282
coconut 2260 2689 2018 287
oil palm 5000 5950 4465 635
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Alphabetical order
avocado 2217 2638 1980 282
brazil nuts 2010 2392 1795 255calendula 256 305 229 33
camelina 490 583 438 62
cashew nut 148 176 132 19
castor beans 1188 1413 1061 151
cocoa (cacao) 863 1026 771 110
coconut 2260 2689 2018 287
coffee 386 459 345 49
coriander 450 536 402 57
corn (maize) 145 172 129 18
cotton 273 325 244 35euphorbia 440 524 393 56
hazelnuts 405 482 362 51
hemp 305 363 272 39
jatropha 1590 1892 1420 202
jojoba 1528 1818 1365 194
kenaf 230 273 205 29
linseed (flax) 402 478 359 51
lupine 195 232 175 25
macadamia nuts 1887 2246 1685 240
mustard seed 481 572 430 61
oats 183 217 163 23
oil palm 5000 5950 4465 635
olives 1019 1212 910 129
opium poppy 978 1163 873 124
peanuts 890 1059 795 113
pecan nuts 1505 1791 1344 191
pumpkin seed 449 534 401 57
rapeseed 1000 1190 893 127
rice 696 828 622 88
safflower 655 779 585 83
sesame 585 696 522 74
soybean 375 446 335 48
sunflowers 800 952 714 102
tung oil tree 790 940 705 100
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Oils and esters characteristics
Oils and esters characteristics
Melting Range deg C
Type of Oil Oil /Fat
MethylEster
EthylEster
Iodinenumber
Cetanenumber
Rapeseed oil, high erucic 5 0 -2 97 to 105 55
Rapeseed oil low eruc. -5 -10 -12 110 to 115 58
Sunflower oil -18 -12 -14 125 to 135 52
Olive oil -12 -6 -8 77 to 94 60
Soybean oil -12 -10 -12 125 to 140 53
Cotton seed oil 0 -5 -8 100 to 115 55Corn oil -5 -10 -12 115 to 124 53
Coconut oil 20 to 24 -9 -6 8 to 10 70
Palm kernel oil 20 to 26 -8 -8 12 to 18 70
Palm oil 30 to 38 14 10 44 to 58 65
Palm oleine 20 to 25 5 3 85 to 95 65
Palm stearine 35 to 40 21 18 20 to 45 85
Tallow 35 to 40 16 12 50 to 60 75
Lard 32 to 36 14 10 60 to 70 65
Oils and their melting points and IodineValues
Oil melting point Iodine Value
Coconut oil 25 10
Palm kernel oil 24 37
Mutton tallow 42 40
Beef tallow - 50
Palm oil 35 54
Olive oil -6 81Castor oil -18 85
Peanut oil 3 93
Rapeseed oil -10 98
Cotton seed oil -1 105
Sunflower oil -17 125
Soybean oil -16 130
Tung oil -2.5 168
Linseed oil -24 178
Sardine oil - 185
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3.3. International standard
The EN 14214is an international standard that describes the minimum requirements forBiodiesel that has been produced from rapeseed fuel stock (also known as R.M.E. orrapeseed methyl esters). It came into effect 30 October 2004.
Property Unitslowerlimit
upperlimit
Test-Method
Ester content % (m/m) 96,5 - pr EN 14103d
Density at 15C kg/m 860 900EN ISO 3675 / ENISO 12185.
Viscosity at 40C mm/s 3,5 5,0 EN ISO 3104
Flash point C > 101 - ISO CD 3679e
Sulfur content mg/kg - 10 -
Tar remnant (at 10% distillationremnant)
% (m/m) - 0,3 EN ISO 10370
Cetane number - 51,0 - EN ISO 5165
Sulfated ash content % (m/m) - 0,02 ISO 3987
Water content mg/kg - 500 EN ISO 12937
Total contamination mg/kg - 24 EN 12662
Copper band corrosion (3 hoursat 50 C)
rating Class 1 Class 1 EN ISO 2160
Thermal Stability - - - -Oxidation stability, 110C hours 6 - pr EN 14112k
Acid value mg KOH/g - 0,5 pr EN 14104
Iodine value - - 120 pr EN 14111
Linolic Acid Methylester % (m/m) - 12 pr EN 14103d
Polyunsaturated (>= 4 Doublebonds) Methylester
% (m/m) - 1 -
Methanol content % (m/m) - 0,2 pr EN 14110l
Monoglyceride content % (m/m) - 0,8 pr EN 14105m
Diglyceride content % (m/m) - 0,2 pr EN 14105mTriglyceride content % (m/m) - 0,2 pr EN 14105m
Free Glycerine % (m/m) - 0,02pr EN 14105m / prEN 14106
Total Glycerine % (m/m) - 0,25 pr EN 14105m
Alkali Metals (Na+K) mg/kg - 5pr EN 14108 / pr EN14109
Phosphorus content mg/kg - 10 pr EN14107p