Hello friends!

I've been silent for a while, but you can see why in this post.  I've just completed my long anticipated processor.  My father and I designed this processor ourselves from the ground up, using both materials we had on hand, and also some materials we had to buy.  The main part of the unit is the 4 steel tanks.  They are 140 gallons each, which make it convenient for doing 100 gallon batches.  The first tank is the reactor, and the other three are washing/drying tanks.  Each of the tanks has a mixer mounted on top of it. The 300 gallon per day figure comes from the fact that in a few hours, 3 batches of biodiesel can be made in the reactor, and pumped into the washing tanks, where they would wash for the remainder of the day and into the night.

 

This is the complete unit.  From right: The green barrel contains methanol. The tote is WVO storage.  We offload from our collection trailer into this holding tank.  The holding tank will eventually have a pre-heater in it, so that less time has to be spent heating it in the reactor, as this takes a while.  On top of the holding tank is the methoxide mixing tank.  This is where we mix our methanol and our caustic soda.  The red hose to it is an air hose.  At the bottom of the tank is a large bubbler, which when opened up, mixes the contents of the tank better than any mixer.  The right most steel tank is the reactor tank.  The rest our wash tanks.  At the left hand side of the unit, you'll notice an air compressor - this is for our bubblers and mixer.  Above that is the filtration system.  On the back of the unit, which I do not have a picture of, are two pumps - one for pumping glycerine out of the first tank and into a barrel (later a methanol recovery system) and another pump pumping dirty water out of our wash tanks.

 

The reaction tank during reacting it's first batch.  You can't read the temperature gauge do to flash glare, but the tank was at about 120 degrees Fahrenheit.  Notice the holding tank to the right, it has two layers in it.  We just offloaded some oil from our collection trailer, and it is darker than our previous collection.  I'll have to remember to mix that up well before I titrate it! 

 

 

 

Our filtration system consists of a 20, 10, and 5 Micron filter.  During filtering our first batch, we never saw much pressure on any of the gauges, we are probably going to step the filtration down to 1 micron.

I brought in a sample of un-filtered, post-wash biodiesel into the chem lab where I go to school at the University of Pittsburgh - Bradford, and ran an FTIR on there, and found that it contained hardly any impurities.  It also had very good analysis, and a flashpoint of 150.  This means that the reactor is working well, that everything is being converted properly, and that the fuel is clean. 

As far as oil colleciton, I have deals with local resturaunts to pick up oil.  Right now I'm picking up 100 gallons a week, and every weekend I produce a batch of about 100 gallon of biodiesel.  I'd like to increase this number as my processor can handle much more than that!

I made my first batch on Saturday.  This biodiesel has been tested out in a chevy diesel engine that my friend had torn apart.  We stuck the fuel lines into a gallon jug of biodiesel, and it was beautiful.  You could hear the difference as it sucked the petro out of the line and began using bio.  This will be powering my dad's 07 Ford F250, and my 86 VW Jetta, and extra fuel is going to be used in a tractor and for off-road use ( have to figure out the road tax issue before we start selling it!)

 Let me know what you think!
 

Outstanding, you guys did a great job. I am glad to see the square tanks as I have been thinking of making the next reactor square. Once again, very nice. You and Dad deserve a big attaboy.

Thanks, raften.  You're right, there aren't a whole lot of reactors out there that use square tanks.  They work just as good as a round one I would say.  We actually picked the tanks up for free, and thats why we decided to go this route.  After some sanding and painting, the tanks were as good as new.  They aren't painted inside, just on the exterior. They aren't stainless, but they are a special type of steel that has been treated, so that they don't rust inside.  They were originally made to handle water with caustic soda, so we don't have to worry about any deterioration of the tanks or getting rust in the fuel.  I'm not sure how regular steel tanks would fare under these conditions, I would imagine that they would have to be coated with something to keep them from rusting.  The tanks also have lids on them, so it keeps the fumes down, but they have hinges and can be opened, or removed entirely if we need in there.  I like to look in the tanks and see how things are coming along :-)

Looks nice overall. One main concern though - you say you are using forced air to mix the methanol and alkali, correct? (that does work well) But, I don't see any vent line coming out of the methanol/catalyst mixing tank, to vent air outside. Where is the vent air (that will be heavily loaded with methanol vapors) going?

 Also, what are you doing for drying?

I forgot to ask, is the reactor insulated?

About lookin inside, I did some serious damage to my airway soft tissue when I was first starting out. I looked inside and breathed in meth/oxide fumes. Plus as a added bonus I got a seven day headache, worst I ever had. Use caution.

My god man!

Amazing job!
Both to you and your father, kudos!!!

I'll be asking lots of questions regarding your setup... WoW!

Hello all, thanks for the comments and questions.  I'd be more than glad to answer any questions you have.  First of all, MikeBrigs is right, using forced air to mix methoxide does create some nasty fumes.  We have a lid on the mixing tank to keep it down, but some still get out.  Until we get a vent to the tank, so the air goes outside, we just do our mixing with the garage doors wide open.  I also wear a gas mask when I am adding the materials to the mixing tank, so that I don't breathe in harmful fumes.

The reactor is not insulated, but it would be a good idea to do that.  It would decrease the heat-up time considerably, and save on electric.  But the electric will soon not be an issue, as we have a diesel generator that we are going to wire up that will provide all the power we need, of course, we are running bio in that. 

As for drying.  I use a bubble wash method to wash the fuel, and when I drain off my dirty water, I dry the fuel.  According my lab results, after my washing, I don't really need to dry, because my freshly washed fuel has no methanol, no water, no impurities, so it's pretty much good to go after a wash.  

WOW! that is a very nice clean looking system, you and your father should be very proud of yourselves.

FrederickBiodiesel:

I also wear a gas mask when I am adding the materials to the mixing tank, so that I don't breathe in harmful fumes.

Unless your gas mask is snorkeled to a fresh air supply, I'm not sure you mask is protecting you. I recall reading a number of posts here, indicating there are no cartridge-based masks that filtered methanol vapors reliablely. From this Methanol MSDS: "wear a supplied air, full-facepiece respirator, airlined hood, or full-facepiece self-contained breathing apparatus.... This substance has poor warning properties." The warning properties refer to cartridges. A cartridge could be completely spent by the methanol, rendering it ineffective. You'd have no warning.

A bit on Methanol as a pollutant:

What effect might methanol have on the environment?

Within 2-4 days of exposure to methanol the effect can be death of animals, birds or fish and death or low growth rate in plants. Long-term exposure can lead to reproductive problems, lower fertility and changes in appearance or behaviour. Methanol generally does not concentrate or bioaccumulate in fish.

How might methanol enter the environment?

If released to the air, methanol breaks down to other chemicals and remains as a vapour for approximately 18 days. It does not bind well to soil and so can enter groundwater.

 This aspect of your process definitely needs to be addressed. The construction on your project looks great, however.

ebztz,  With the doors open, the fumes don't get bad in there.  Maybe the mas is protecting me, maybe it's not, all I know is that when I'm around that mixing tank when the air is on, I can't breathe if I don't have the mask on, and I can breathe with it on.  So it is doing something for me.  Other than that, the fumes aren't bad.  I don't think it's enough to pose a health hazard or an environmental problem.  One of the things I would like to do, so that I can process inside when it's cold, is to have some vents to the outside that will take care of the fumes.

Another thing I would like to do, if I can find it, is to start using ethanol instead of methanol.  I've heard it's less toxic and better for the environment.  My oil titrates low enough I could be using ethanol, if I could find it. 

FrederickBiodiesel:

With the doors open, the fumes don't get bad in there.

Good for you, potentially bad for air quality and other living things, outdoors. Also wasteful, as Methanol isn't inexpensive. Many homebrewers go through great lengths to retain and recover Methanol for these reasons.

Maybe the mas is protecting me, maybe it's not,

It's your health at risk, not mine. Do a search here for "mask" and you find discussions with statements like:

"The only respirator that's Methanol proof is a contained air unit"

"Most people go with the "Hold your breath at crucial moments" technique while at the same time working "up-wind" However, you could also use a SCUBA type positive air supply or diving hose and mask."

"I have been reading everything I can find on biodiesel the last few weeks and continue to run across this statement: 'CARTRIDGE RESPIRATORS DO NOT WORK WITH METHANOL'"

Or this statement from RickDaTech, found here:

"There is no respirator that will stop methanol fumes..." 

all I know is that when I'm around that mixing tank when the air is on, I can't breathe if I don't have the mask on, and I can breathe with it on.

If you have a high enough concentration to inhibit respiration, you're poisoning yourself.  

I don't think it's enough to pose a health hazard or an environmental problem.

Presumptuous, considering the lack of concern you've shown for your own safety.

One of the things I would like to do, so that I can process inside when it's cold, is to have some vents to the outside that will take care of the fumes.

...or you could alter your Methanol/catalyst mixing so the system is sealed, minimizing the possibility of polluting and poisoning. 

Another thing I would like to do, if I can find it, is to start using ethanol instead of methanol.  I've heard it's less toxic and better for the environment. My oil titrates low enough I could be using ethanol, if I could find it.

Yes, Ethanol (drinking alcohol) is certainly safer. You can consume it and you won't go blind - "As little as four milliliters can cause blindness and 80 to 150 milliliters can be fatal; about half a milliliter per kilogram of weight is deadly."

I'm sorry that I came off as if I didn't care about the Methanol.  I realize that methanol is poisonous, and that contact with it or it's fumes is not good.  Now, maybe cartridge filters don't filter out methanol very well.  But the ones I have seem to do a decent job.  You know, you have to do some stuff manually, like open a lid and put lye into a container of methanol, so you don the respirator, stand upstream and try not to do it as quickly as possible without breathing too much. It's just a safety precaution really, until we get something better in place. As I stated, we just built this processor, and have only run one batch through it so far.  It is a learning process.  One of the things we are learning is that we need to have a better system in place for handling the methanol.  We will be building a methanol recovery system soon.  We are also going to make the mixing tank more airtight, with a vent to the outside.  Of course I care about my health, and the environment, and that's why I stated that I'm going to be doing some recovery, and also am looking into ethanol.  Heck, it's in my best interest to do recovery.  If there's methanol fumes in the air, that's money that is being blown away! Besides that, I would argue that our system is at least as safe as many other designs and kits out there.  Anyways, thanks for your constructive criticism, and rest assured that we are taking our methanol handling seriously.

Excellent response; from the looks of your machine, I'm sure you'll have no troubles devising a safer methanol handling/mixing system.

I've heard enough "poisoning" stories, so I wanted to make sure you're being safe. Make sure you read the precautions on your filter cartridge packaging.

FrederickBiodiesel:

Hello all, thanks for the comments and questions.  I'd be more than glad to answer any questions you have.  First of all, MikeBrigs is right, using forced air to mix methoxide does create some nasty fumes.  We have a lid on the mixing tank to keep it down, but some still get out. 

It has to get out, since otherwise you would be pressurizing the tank - and those plastic tanks can't take much pressure. I *highly* recommend sticking a vent line on there. If you can't tap a threaded connection into the tank, just drill a hole in there, and attach a hose barb connection (preferably plastic welding it on, if not, marine epoxy seems to work pretty well - as long as methanol doesn't come in direct contact. I'm not sure how much methanol vapors would eat it up).

 Until we get a vent to the tank, so the air goes outside, we just do our mixing with the garage doors wide open.  I also wear a gas mask when I am adding the materials to the mixing tank, so that I don't breathe in harmful fumes.

That won't help you with methanol vapors. They go through organic cartridge respirators in a matter of a few minutes or less.

As for drying.  I use a bubble wash method to wash the fuel, and when I drain off my dirty water, I dry the fuel.  According my lab results, after my washing, I don't really need to dry, because my freshly washed fuel has no methanol, no water, no impurities, so it's pretty much good to go after a wash.  

You want to get the dissolved water as low as possible, which is a significant factor in needing drying. The water test you presumably had done was centrifuge based? That only shows free water. The reason you want to reduce the dissolved water is that as the temperature drops, the saturation level of wter in biodiesel drops, and if you're just barely below saturation, it won't take much temp drop to give you free water fallout (also if you mix it with diesel, that drastically reduces the saturation level).

FrederickBiodiesel:

I'm sorry that I came off as if I didn't care about the Methanol.  I realize that methanol is poisonous, and that contact with it or it's fumes is not good.  Now, maybe cartridge filters don't filter out methanol very well.  But the ones I have seem to do a decent job.  You know, you have to do some stuff manually, like open a lid and put lye into a container of methanol, so you don the respirator, stand upstream and try not to do it as quickly as possible without breathing too much.

Or you could put the catalyst in first, and pump the methanol into the tank second (preferably *through* the catalyst), with a proper vent on the tank (venting through a condensing column to condense methanol vapors as much as possible, and then venting outside).

It's just a safety precaution really, until we get something better in place. As I stated, we just built this processor, and have only run one batch through it so far.  It is a learning process. 

Yup. And we're just giving you some tips on making it safer.

 

You indicate you are considering using ethanol instead of methanol in your process.  My understanding is that the main problem with ethanol is getting anhydrous ethanol, as it doesn't take much water to poison the reaction.  I have seen reports posted that E85 is a workable source of anhydrous ethanol, but of course you need to account for the 15% gasoline in the mixture both in making sure you have the proper amount of ethanol for your process and to remove the gasoline from your final product.  So if there is an E85 pump available to you this might make it easier for you to see if you can make ethanol work.

Mike,

In regards to how to tested for water in the fuel was by doing an FTIR in the chemistry lab at my university.  I'm not sure if everyone is familiar with this, but what it does is uses infrared to analyze the contents of a substance.  For example, when I put my biodiesel into it, it came back with a graph, showing my stretch of methyl esters.  If there was any methanol in there, it would show up as it's own little stretch on the graph, and there is also an area where water would have shown up. It will also show a stretch for glycerin if there is any, and even a stetch for free fatty acids. So, chemically, no, there isn't any water in my fuel, or is there any methanol, or glycerin, or anything that would be a problem.

When my school gets the new gas chromatograph, I can test further.  As of right now, I can say that the biodiesel I made in this processor has ran straight B100 in my Jetta for 100 miles without any problems.  My dad is running it mixed with petrodiesel in his new Ford truck (about b50) right now and it seems to be doing fine as well.

Yes, we are currently working on venting our methoxide tank.  The lid will be made airtight, with a vent going to the outside, and we have just made a basket to go inside the tank that holds the lye in place whilst the methanol is pumped into the tank.

Unfortunately, there are not any E85 pumps nearby at which I can obtain ethanol.  I'm not giving up on this idea though, I am going to try to track down somewhere where I can buy ethanol.  My methanol supplier may be able to point me in the right direction.  However, if it is more expensive, then we may stick with methanol.  We are also going to try using KOH instead of NaOH. 

FrederickBiodiesel:

Mike,

In regards to how to tested for water in the fuel was by doing an FTIR in the chemistry lab at my university.  I'm not sure if everyone is familiar with this, but what it does is uses infrared to analyze the contents of a substance.  For example, when I put my biodiesel into it, it came back with a graph, showing my stretch of methyl esters.  If there was any methanol in there, it would show up as it's own little stretch on the graph, and there is also an area where water would have shown up. It will also show a stretch for glycerin if there is any, and even a stetch for free fatty acids. So, chemically, no, there isn't any water in my fuel, or is there any methanol, or glycerin, or anything that would be a problem.

It's just not possible that there is "no" water in your fuel after washing, without using molecular sieves or vacuum distillation or some other means to get all of the dissolved water out. Most biodiesel at room temp has a saturation of around 1500 ppm of dissolved water. If left exposed to air, it will reach equilibrium with the air as far as degree of saturation (so if the air is 50% humidity, the biodiesel will have 750 ppm dissolved water). So, if the FTIR told you there was 0 *total water* (free+dissolved), I would question its accuracy.

When my school gets the new gas chromatograph, I can test further.  As of right now, I can say that the biodiesel I made in this processor has ran straight B100 in my Jetta for 100 miles without any problems.  My dad is running it mixed with petrodiesel in his new Ford truck (about b50) right now and it seems to be doing fine as well.

Personally I wouldn't count that as a test of its quality. I'd recommend doing a Warnqvist test as a simple means of assessing degree of conversion. Washing should definitely be removing residual methanol and free glycerin, but won't do anything for unreacted glycerides. And of course will mean you have to have *some* dissolved water in there, unless you explicitly make efforts to remove all of the free and dissolved water, and then keep the biodiesel frmo being exposed to air.

You note that you go to school in Pittsburgh.  This web site shows stations in the Pittsburgh area offering E85 for sale:

http://www.e85refueling.com/ 

So perhaps it is available and you were unaware of it! 

 

dhdurgee,

Thanks for the information!  I didn't know e85 was available here.  I live North of the burgh so I never really go by where those stations are located, but I think I might have to try some.  I started a new thread in Biodiesel Production dealing with using e85 to produce biodiesel.