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Integrated solar-biomass technology for production of green power and products
Chris Leech, Cody Cleaver, Ahmad Majzoub, Warren Furnival, Helen Lockhart
University of Western OntarioDepartment of Chemical and Biochemical EngineeringCBE 4497 Plant Process and Design
PFD Section 300 - Biodiesel Production
P-103 A/B
S-302
ST-301 ST-302
MX-301
ESTER-301
ESTER-302
HX-301
0.1
S-308
0.1ES/Out S-311 CENT-301
HX-302
HX-303
0.4
S-316
REMEOH
METHANOL
S-303
CATALYST WZA
S-304
SEP1-TOP S-313
SEP1-BOT
RCU-301
0.1
S-342
GLY-H20
CENT-302
WASTE ST-305
FATTYM
GLY-H20 HX-306
CD-303
GLY-H20
0.4
S-356
HX-307
0.4
S-349
CENT-303
HX-312
VDRYER-301S-337
OIL TRUCK-305
HX-3100.1
S-364
0.1S-312
VAP ST-301
S-338
0.1
S-340
HX-304
CD-301
HX-305
CD-302
GS-301/3
0.1
S-322
MX-302
0.4
S-343
Dist-301
0.1
S-323
0.1
S-320
0.1
0.1
S-321
0.1
0.4
SEP-302
0.4
S-353
S-354
0.4
S-3510.4S-352
0.1
S-335
S-336
MBTE Storage Tank
P-301S-306
0.1
S-319
DCV-301
P-302
P-303
S-362
P-301S-314
S-3410.1
PV-304
0.1S-324 S-325
Section 300- Transesterification
0.4 307
0.1S-344
S-345
P-304
S-348
SP-301
SP-302
SP-303
0.1
S-363
P-303
Oil from Extraction Section
Mem-301
0.4
S-310
Fatty Storage-301
0.1
S-309
FD-301
S-329
0.1
S-330
S-327
0.1
S-328
S-326
CSTR-301
S-357GLYCERIN
MX-303
S-355
M-304
0.1
S-332
Vacuum Flash-301
S-339
S-358
0.1
S-360
0.1
S-361
0.4
S-350
S-346
S-347
S-333S-334
S-301
S-307
0.4
S-305
333
0.1
S-318
S-331
0.1 298
0.2
0.1 0.1
0.1
0.1
0.1 0.1
0.1
0.1
0.1
0.20.1
0.1
0.1
0.1
0.1
0.1
0.1
0.10.4
0.1
1.72
298
298 298
298
298 298
320
300
380
350
298
2980.4
333
300
298
298
370
298
298
318
298
298
318
370
318
370
306
333
298
298
298
298
298
298298 333
333
333
330
370
298
298
298
298
330
298298
298
298
370
289
330
306
0.4 306
300
0.1 300
S-315
298
298
298
S-317
CW ST-308
S-364S-365
MV-301
0.1
298
Transesterification
FAME
Glycerol
WVO
Methanol
Innovation of Biodiesel Production
Glycerol-based fuel additive assists Decreasing in particulate emissions Act as cold-flow improvers Viscosity reducer
CSTR
C57H104O6 + 3CH3OH ↔ 3C19H36O2 + C3H5(OH)3 Total Volumetric Flowrate = 18,500 L/day
Residence time= 2.2 hrs
CSTR practical issues, key design considerations/challenges
Potential Problems Problem with high viscosity in algal oil when being
treated Formation of acrolein
highly toxic substance formed by thermal decomposition of Glycerol
Glycerol-based fuel additive increases biodiesel quality/commercial value Substrate used is Isobutylene Etherification is the transformation
process Catalyst used: Amberlyst-15
Benefits
Environmental Assessment Minimizing environmental impact of
waste streams
Only one waste stream: waste water
Our methanol is fully recycled and reused
Glycerol utilized as fuel additive instead of waste stream
Alternative CSTRs considered
CSTR vs Batch Reactor Utilizing methanol vs ethanol as alcohol Membrane vs Centrifuge
Catalyst
Acid
AlkalineEnzyme
Not influenced by FFA
Saponification
Not used commercially Sensitivity to purity of reactants
Research
Slower reaction
CSTR assumptionsAssumptions97% conversion is achievedRecycled vent gasses are mostly methanol
Reference temp.= 25 oC (298.15K)Cp values calculated with empirical formulas
2:1 height to diameter ratioPlant height restriction at 5 m
Detailed Design Calculations H:D ratio is 2:1, or R = 2
Where V is the volume (m3), and the height H is given by:
Detailed Design Calculations The power requirement [W] :
Therefore, the number of impellers (Ni ,rpm) was found using the correlation given in Haynes (2004):
Where k2 is the proportionality constant, ρ is the average fluid density, and Di is the impeller diameter.
CSTR Reactor CAD Design
CSTR sketch/dimensions/internals
Volume of reactor = 12.6 m3
Conical shape for bottom of reactor volume =0.5 m3 ,height = 0.5 m and diameter
= 2 mUnit Cost: $59,800Width of baffle: 0.09 mType of Impeller: Rushton TurbineBaffles: Carbon Steel Type 405Blades: Carbon Steel Type 410Material: Austenitic Stainless Steel (IS: 1570-
1961)Wall thickness: 135.91 mm
Process and Instrumentation Design
Simple Feedback Top Control
Flow controller for Algal Oil/Methanol/WZA volumetric flow
Level Controller utilized to prevent overflow
Temperature Transmitter maintains temp. at 65C
Supervisory Process Control allows all units to relay information to Process Logic Controller
Pneumatic valves set up for temp. and pressure regulation
Innovation in Biodiesel Production
Glycerol-based fuel additive assists Decreasing in particulate emissions Act as cold-flow improvers Viscosity reducer
Commercial Value for: Biodiesel reformulation Octane booster Decrease cloud point of diesel fuel
when blend with biodiesel
Economic Analysis
Total Equipment Cost
$13,162,500
Total Capital Investment
$11,210,000
ProfitabilityPrice $/tonne Price USD
FAME 868.21 7,000,000Glycerol 680.00 710,000
Tax Exemptions
200.35 1,603,000
Annual Sales Revenue
$9,250,000
Price $/gallons
FAME 2.95Glycerol
Profitability
ExpensesDirect 5,690,000Indirect 443,000General 1,030,000Annual Total Expense $7,160,000
Annual Net Income 2,080,000
Payback Period 5.4 years
Return on Investment 18.6%