may 5, 2015 team 14: gre-cycleteam 14: gre-cycle
TRANSCRIPT
May 5, 2015
Team 14: GRE-cycle
The Team
Left to right: Colton Walker, Ben Guilfoyle, Hannah Albers, Melanie Thelen
1/10
Introduction
• Need for renewable fuels
• Waste product feed• No ethical implications
• Full-scale production• 9.5 million gallons/year
• Proof of concept https://dieselgreenfuels.files.wordpress.com/2012/03/biodiesel-pump.jpeg
Process
Pre-Treatment Reactor
Simulation
Economics
Introduction
2/10
Takeaways
Process Flow Diagram
Process
Pre-Treatment Reactor
Simulation
Economics
Introduction
3/10
Takeaways
NaOH
Pre-Treatment
▪ Restaurant grease modeled as soybean oil with 29% free fatty acids (FFA)
▪ FFA esterified to biodiesel– Plug-flow reactor
– 3.5 m3
– 1% FFA
▪ Membrane filtration
▪ Methanol recovery via distillation
Process Pre-Treatment
Reactor
Simulation
Economics
Introduction
4/10
Takeaways
Pre-Treatment Reactor Volume
1.00 1.50 2.00 2.50 3.00 3.50 4.000.0%
0.5%
1.0%
1.5%
2.0%
2.5%
Effect of Pre-Treatment Reactor Volume on FFA Composition
Reactor Volume (m^3)
wt
% F
FA
Process Pre-Treatment
Reactor
Simulation
Economics
Introduction
5/10
Takeaways
Distillation Tower
▪ Key Specs– 9 trays
– 1.5 reflux ratio
Process Pre-Treatment
Reactor
Simulation
Economics
Introduction
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Takeaways
Main Reactor▪ Plug-flow via Polymath
and UNISIM– NaOH catalyst
– 96% soybean oil conversion
– 1.5 m3
▪ 2 membrane filters and setting tank
▪ >99% methanol recovery
http://www.coe.or.th/coe/main/coeHome.php?aMenu=701012&aSubj=98&aMajid=7
0 300 600 900 1200 1500
0 5 10 15 20 25
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
1500 L PFR with 13 min residence time
4000 L Batch with 25 min reaction time
PFR Reactor Volume (L)
Co
nve
rsio
n
Batch Time (min)
Process Pre-Treatment Reactor
Simulation
Economics
Introduction
7/10
Takeaways
Simulation
Click icon to add picture
• UniSim (continuous process)
• SuperPro Designer (batch)
• Polymath (kinetics)
UniSim
SuperPro DesignerPretreatment Reactor
Reactor Type
Batch PFR
% Conversion
90.31 95.19
Volume (m3)
5.32 3.50
Agitation Yes No
Cost $18,145 $7,520
Process Pre-Treatment Reactor
Simulation
Economics
Introduction
8/10
Takeaways
Economics
• Guthrie analysis used to estimate costs
• 10% rate of return
• Economic advantage over competitors• $3.41/gallon• Not profitable without gov’t
subsidy
Process Pre-Treatment Reactor
Simulation
Economics
Introduction
9/10
Takeaways
Total Capital Costs $ 9,279,005.80 Total Hourly Costs $ 4,994.53 Total Hourly Income $ 6,068.95 Total Hourly Profit $ 1,074.42 Total Yearly Profit $ 8,595,353.28
Takeaways
• Data not always readily available
• Not one “right” answer
• Communication
• Simulation does not equal reality
• Alternative energy still needs
improvement
Process Pre-Treatment Reactor
Simulation
Economics
Introduction
10/10
Takeaways
Acknowledgments
• Professor Jeremy VanAntwerp
• Randy Elenbaas
• Doug Elenbaas
• Calvin Dining Services
• Professor Baker
• Professor Looyenga
Questions
Back-Up Slides
Pre-Treatment Reactor
Process Pre-Treatment Reactor
Simulation
Economics
Introduction
5/7
1.00 1.50 2.00 2.50 3.00 3.50 4.000.0%
0.5%
1.0%
1.5%
2.0%
2.5%
Effect of Pre-Treatment Reactor Volume on FFA Composition
Materials of Construction
Vessel MOC
Feed Storage Tank Carbon Steel
Methanol 1 Storage Tank Carbon Steel
Sulfuric Acid Storage Tank Stainless Steel 316
NaOH Storage Tank Rubber lined Carbon Steel
Methanol 2 Storage Tank Carbon Steel
Biodiesel Storage Tank Carbon Steel
Glycerin Storage Tank Carbon Steel
Mixer-100 Carbon Steel
Mixer-101Stainless Steel Lined Carbon Steel
Mixer-102 Carbon Steel
Mixer-103 Carbon Steel
Distillation Column Stainless Steel 316
Membrane 1Stainless Steel Lined Carbon Steel
Membrane 2 Carbon Steel
3-Phase Separator Carbon Steel
Pre-Treatment ReactorStainless Steel Lined Carbon Steel
Transesterification Reactor Carbon Steel
Feed Composition
0 200 400 600 800 1000 1200 1400 1600 1800 20000
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
Jatrophas
Soybean
PFR Reactor Volume
Tri
gly
ceri
de C
onvers
ion
Fatty Acids WCO Soybean OilSunflower
oilJatrophas
OilLinseed
Oil
Linoleic Acid43.85
% 43-56% 44-75% 19-41% 17-24%
Linolenic Acid 4.65% 5-11% -- -- 35-60%
Oleic Acid33.75
% 22-34% 14-35% 37-63% 12-34%
Palmitic Acid13.62
% 7-11% 3-6% 12-17% 4-7%
Stearic Acid 4.14% 2-6% 1-3% 5-9.5% 2-5%
http://onlinelibrary.wiley.com/doi/10.1002/cjce.21848/full#cjce21848-note-0001
http://www.chempro.in/fattyacid.htm
Type Description Advantages Disadvantages
Batch tank with agitation
handles variable feed compositions long total reaction time
increased conversion with agitation complex control systemlow capital costs Simple
Plug-Flow (PFR)tubular reactor with no
radial dispersion
high conversion higher volume reactor is necessarycompatible with liquid catalysts less complex control system Simple
Packed Bed (PBR)tubular reactor with solid
catalyst
compatible with CaO, heterogeneous catalysts
not compatible with liquid catalyst
Simple long tube lengths long residence time required requires catalyst regeneration
Continuous stirred tank (CSTR) vessel with agitation; continuous
simpleseveral reactors in series needed for high conversion
Membranemembrane selectively
permeable to methanol and biodiesel product
eases downstream separationsmembrane must be occasionally replaced
variable materials of construction long reaction timelow operating costs handles variable FFA content
Micro-reactorPFR with smaller
channels
made from plastic resins to mitigate corrosion
lower FFA content required
high conversion with shorter reaction times
Microwavebatch process that heats
reactants through microwave radiation
high conversion with shorter reaction times difficult to scale up to industrial size
difficult kinetic modeling
Type Description Advantages Disadvantages
Cavitational
continuous reactors that generate cavities that grow and collapse to
create emulsions
lower methanol:oil ratio; easier downstream separation
difficult to scale up to industrial size
increased mass transfer; high conversion higher energy requirement
higher operating cost
Oscillatory Baffled (OBR)PFRs with evenly spaced
baffles and oscillating flow throughput
compatible with homogeneous and heterogeneous catalysts
higher energy requirement
increased mass transfer; high conversion higher operating/maintenance costs
some have built-in methanol recovery system
Reactive Distillationreaction and methanol
separation take place in distillation column
Eases downstream separations complex control systemaverage conversion high operating/maintenance costs high energy requirements incompatible with feedstock
Transesterification Kinetics
