getting started in on-farm biodiesel production - attra · getting started in. on-farm biodiesel...

Getting Started in On-Farm Biodiesel Production

By NCAT energy specialists Al Kurki and Rich Dana

A curriculum for agricultural producers

The National Center for Appropriate Technology • www.ncat.org • 1-800-275-6228 (1-800-ASK-NCAT)

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.

www.attra.ncat.org

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 examplesRapeseed. Photo by Marek Luty, courtesy of www.sxc.hu.


Introduction: what is biodiesel?

Photo by Howard Haines, MT DEQ.

• 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


Advantages of biodiesel• Biodegradable

• Non-toxic

• Favorable energy balance – 4.5:1 for soy biodiesel

• Favorable emissions profile

Photo courtesy of USDA ARS.


Biodiesel reduces toxic emissions


Advantages of biodiesel• 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

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




Safety first! Check with local regulations• NCAT webinar on biodiesel safety and permits

– Jan. 14, 2010



• Safety first

• No blender batches


Small batch processing

VegetableOil

• 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



ReactorVegetable

OilReactor

• “Batch” method as opposed to continuous processing



ReactorVegetable

OilReactor

catalyst

• Remember: Methoxide handling is the most dangerous step in the process



Photo by Lee Honeycutt



Reactor

ReactorReactor

• Full reaction in about an hour



ReactorBiodiesel

Glycerol• Compost

• Fertilizer

• Soapmaking

• Biodigester

• Feed

• Do you have a plan to deal with the excess methanol?


www.dickinson.edu/departments/sustainability/biodiesel.html


Photos courtesy of Dickinson College.



ReactorBiodiesel

ReactorWash Tank

water spray



Reactor

ReactorWash Tank

water spray



Reactor

ReactorWash Tank

wash-water treatment



Reactor

“Dry” fuel by re-circulating through a shower- head, or simply leaving in an open barrel in the sun.


Small batch processing equipmentCommercially available batch processors: $3,000 - $10,000

Homebiokits.com


Small batch processing equipmentCommercially available batch processors: $3,000 - $10,000

Homebiokits.com www.northerntool.com


Small batch processing equipmentHomemade processors: $200 - ?

Photo courtesy of www.girlmark.com.

“Girl Mark”- Maria Alovert,Originator of the Appleseed Processor

www.girlmark.com


Pitfalls

• 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)

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.


Farm-scale oil presses• 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

Photo by Amanda Lowe, NCAT.


• 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/oil-seed.html

Oilseed presses

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 105Canola 1,461 43 59Sunflower 1,429 40 53Safflower 1,592 33 49Soybean 2,376 19 42Corn 8,618 4 32Camelina** 569 35 19Cottonseed 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

Photo courtesy of USDA ARS.Source: Evaluation of Biodiesel from Camelina Sativa Oil, Nestor Soriano, MSU-Northern Bio-Energy Innovation and Testing Center, May 2008.


Keep in mind...• 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?



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 worker- and 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.coopwww.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



Rocking Z biodiesel costs 2008

Price comparison of Rocking Z biodiesel

Unit price This batchMethanol $3.43/gallon $60.37Catalyst $2/pound $20.04Oil $1.10/gallon $87.80

Total $168.01Biodiesel recovered 73 gallonsEfficiency 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


Next ATTRA biodiesel webinars:

Safety and Permits, January 14, 2010

Taxation and Production Incentives, March 25, 2010

www.attra.ncat.org • [email protected]

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getting started in on-farm biodiesel production - attra · getting started in. on-farm biodiesel...

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