Biodiesel PLANT EXPERTISE & TECHNOLOGY


Total services for Turnkey solutions


Feasibility & pilot plant studies
Project management
Quality control / expediting
Start-up / performance testing
Process design / detailed engineering
Procurement and manufacture
Field supervision of installation
Operator training

We are a leading global supplier of Distillation Systems, & Evaporation Systems, Drying Systems and Spray Drying systems with more than 600 installations in India and Abroad.

The systems designed by our Group have impressed the globe which includes countries like - U.K., Canada, Mexico, Turkey, Iran, Malaysia, Thailand, Nigeria, Egypt, Srilanka, Bangladesh, Pakistan, Nepal, Indonesia, Saudi Arabia, U. A. E., China.

Our Group has Working Experience with world renowned Engineering
Consultancies in quality control and project execution which includes:

Kvaerner Powergas Ltd.
UHDE India Ltd.
Humphreys & Glassgow
Dalal Engineering
Technimont ICB
Engineers India Ltd.

With the team of more than 150 dedicated technical personnel, our technology group offers wide range of turnkey process plants which include the following:

Fuel ethanol plants
Zero discharge plants (distilleries, pharma, chemicals)
Evaporators (falling film/ forced circulation)
Spray / flash / rotary drying plants
Starch and starch derivatives plants
Pollution control equipments – incinerators / calciners,
Bag filters, flue gas spray scrubbers.

Experience

We have wide experience and proven expertise for Single source supply of complete range of distillation – dehydration, drying & evaporation systems. Our Technology encompasses cost competitive turnkey solutions. simple to highly integrated complex systems.

Some of our groups successfully designed, installed and commissioned unique Biofuel plants are as under:

Molasses based/beet juice/grain based multi-pressure distillery plant with integrated spent wash
   evaporator and zero discharge.
Atmospheric pressure distillation for vodka grade alcohol at Turkey.
More than 8 fuel ethanol plants based on molecular sieve technology
Improvement of fermentation efficiency in 3 existing distilleries in India.
Methanol recovery plants for specialty starches in India and Bangkok.
Short path (molecular) distillation system at Turkey.
Distillation system at Turkey for waste crude to distil kerosene and higher fractions.
Distillation plant based on grape fermented wash in Istanbul, turkey.
Biomethanated spent evaporator for molasses based distillery for Punjab, India.


Biodiesel PROCESS

Biodiesel is the main product. The planned capacity will be produced as per EN14214 and American Standard / International Standards per year and the equipment specified by us is designed to achieve the specified targeted products when operated correctly.

Our groups proven Technology, design and impressive economics of operations and process technology to generate and treat non-toxic/neutral waste meeting Pollution Board norms after Diesel processing and final production is widely acclaimed and accepted worldwide.

Glycerin

The glycerin produced as a by-product of Biodiesel production has a purity of 40% - 70%. Our proven technology process and design enables the glycerin to be distilled to pharmaceutical glycerin (up to 99.5% purity).

Technical Background

Methyl ester of vegetable oils (FAME – fatty acid methyl ester) are now readily accepted as an alternative fuel for diesel engines. FAMEs are produced from renewable sources and exhibit an ecologically friendly profile of a combustion fuel. They can be blended with classic diesel fuel in any ratio and can be used in diesel engines without any necessity to modify the engines while maintaining or improving engine performance. The increased use of such fuels is a worldwide trend. The goal for EU countries is to ensure 5.75% of all liquid fuels used should be based on renewable sources by 2010.

The key feature of the process is the transesterification of cold or hot pressed vegetable oil by methanol in the presence of an alkaline catalyst in a one-step operation occurring at elevated temperature and pressure, followed by subsequent final treatment consisting of dry washing, extraction of glycerin and final polishing. Using the process recommended in this proposal, no ecologically harmful waste or waste waters are produced.

Transesterification – Chemical reaction

Transesterification is the displacement of alcohol from an ester by another alcohol in a process similar to hydrolysis, except that an alcohol is used instead of water. This process has been widely used to reduce the viscosity of triglycerides.

The process technology and design of our group is well acclaimed and accepted for end products (Biodiesel) quality and quantity meeting international standards.

Settling of Biodiesel

Instead of leaving Biodiesel to settle in special tanks, which takes a lot of time, we propose centrifuges for Biodiesel and glycerin separation. These centrifuges are designed specifically for extracting glycerin from Biodiesel.

Waterless treatment

Water in the raw material present a big problem in Biodiesel production. We do not use water to wash Diesel in our system. Other suppliers use water to wash Biodiesel. The great problems of removing the water from the product after washing are time consuming, expensive and often ineffective and contaminating.

Methanol Recovery

The proposed Methanol Recovery Units recover up to 40% of methanol if a Methanol rectification tower is added to the proposed set up. This can greatly reduce the overall cost of Methanol per batch.

Final Biodiesel Polishing Process

Dry Wash : Following methanol removal, the biodiesel undergoes waterless wash. The Biodiesel is subjected to a chemical reaction using a specialized reacting agent which reacts with the unwanted material in the biodiesel.

The final product is absolutely pure and dry. The reacting agent needs replacing at the rate of about less than 1% of the total volume per batch of biodiesel processed. The reacting agent after use is rendered neutral and nontoxic. It is not a hazardous waste and may be used as landfill.

Final Polish : The final polishing is subjected to a filter unit that removes all extremely fine particulates that may have escaped through the processing lines. We have specially designed Biodiesel polishing units, which remove even the smallest particulates by filtering the Biodiesel to 1 micron. The Filter unit is designed for continuous operation. Due to flexible design, the filter elements can be easily changed without shutting down the process plant.

Storage : Thebiodiesel after final polishing and filtering is ready for sale or storage. T he fuel needs necessarily to be kept at temperatures above 38 degrees Fahrenheit. Biodiesel should not be stored for more than six months prior to use. Nitrogen blankets may be used to help protect your finished product. Heated tanks may be necessary if fuel is to be stored for longer time in cold climate conditions less than 40 degrees Fahrenheit.

Automation and Safety: The whole process is fully automated. The running of the plant can be overseen via a LCD monitor. Safety has been brought to the highest level. The process is continuously monitored to help spot variances that could endanger the production from a safety perspective the whole system is designed to be fail safe.

Support : Our group assures successful installation and commission of the plant as per the agreed input and output paraments. We offer complete support for a successfull installation and commissioning of Biodiesel plants as per our specifications. Also, our service engineers are at your disposal 24 hours a day through the whole period of Biodiesel production.

We recommend that customers take out an Annual Maintenance Agreement which is priced at a very negligible value of all the equipment in the plant to be maintained each year.

Our Groups Technology acclaimed and accepted worldwide guarantees you success in quality Biodiesel Production all the way.

Description of Transesterification Process

The whole plant is fully automated. Its operation is controlled using an LCD monitor.

  1. The removal of particulates from feed stock oil.
  2. The oil is pre-heated to 60Degree C in pre-heating tanks.
  3. Methanol and NaOH (or KOH) are added to the methoxide mixer
  4. After methoxide has been prepared, pre-heated oil is pumped into the processor.
  5. The Temperature is raised to 85 Degree C, the processor operates under a pressure less than 1 bar.
  6. After the correct temperature has been reached, the processor automatically maintains it during the chemical reaction. The whole process finishes in approximately 90 minutes. A new cycle can be started once the Biodiesel produced is transferred under pressure from the processor to a pressurized tank where methanol is recovered.
  7. The Methanol Recovery Unit will extract excess methanol from Biodiesel. In theory, it is possible to recover upto 43% of the methanol.
  8. After the methanol is recovered, the process of separating Biodiesel and glycerol using centrifuges begins.
  9. Following the removal of glycerin from the Biodiesel, it is transferred to a washing station where it is filtered with the help of a special reacting agent.
  10. The Biodiesel is dried using a nitrogen generator.
  11. In order to be sure that the Biodiesel is 100% clean, it is polished, which means that it is filtered to 1 micron.
  12. The resultant Biodiesel is ready to be used and provided the specifications of ingredients have been met and the process followed correctly, it will meet the EN14214 standard.

Raw Material Requirement and Parameters

The system can handle a large variation of both vegetable and animal fats. For the system to produce for, eg. a fuel corresponding to the European norm EN 14214 and American Standards, the feedstock has to be at least within the parameters well defined. The parameters of Raw Material are quite elaborate and will be furnished separately on request.

Methanol Parameters

The specification of Methanol should be of technical grade, >99.85% purity although upto 2% isopropyl alcohol content is admissible, water is not.

Chemical formula : CH3OH
Purity : 99%
Specific density : 792 kg/m3
Melting Point : -98 C
Boiling point : 64.51 C

Catalyst Parameters

Potassium hydroxide or Sodium hydroxide should be industrial grade, 99.9% pure, in pearl form. The amount of catalyst to be used will vary between 4 and 8 grams of sodium hydroxide (caustic soda / NaOH) or 5.6 to 11.2g (KOH) per litre NaOH and KOH can be used as catalyst.


Biodiesel Parameters

To meet the EN 14214 standard and American standards, the Biodiesel produced must meet the specific parameters. These elaborate parameters will be furnished on special request separately.


Alternative Feedstock for Biodiesel Production

Our Groups proven Technology enables Biodiesel production from various alternative feedstocks ie from all variety of edible and non-edible oil seeds like Jathropha, soya, Palm Oil, Algae etc… and various animal fats.

Technology process and details for alternative feedstock’s for Biodiesel production will be offered on request appropriately to potential prospective producers.