Our highly praised BDT-series processing units are the harvest of the effort. By looking outside the realm of contemporary biodiesel processing, Biodiesel Technologies has integrated scientific solutions from industries all over the world, in production quality, system automation, chemistry, filtration, and efficiency. Biodiesel Technologies’s benchmark leadership continues to provide the Biodiesel industry with breakthrough advantages. The Biodiesel Technologies Processing Advantage produces the highest quality biodiesel, significantly exceeding all minimum standards for quality established by ASTM D6751 specifications. Today, our touch screen computer controlled systems, conceptualized by BDT team and manufactured by one of India’s leading process automation company are setting the pace for others to follow.
The fact that all our BDT-series processing units are modular and have extremely low operating cost, is further example of Biodiesel Technologies, Kolkata, India’s commitment to our customer’s needs.
Our company was founded upon the ideal of creating a greener world. Biodiesel Technologies’ process removes all water content in the first stage of processing and never reintroduces water in the subsequent stages, thus completely eliminating the risk of adding waste or contaminated water to our already taxed environment. Our pledge to the environment and the biodiesel industry is to create clean systems that have zero waste stream, now and in the future.
Biodiesel Technologies builds in versatility for an ever changing world. All BDT processing units can accept raw materials from a wide range of feedstock with an acid value of five percent or less. This advantage allows our customers to select feedstock based on availability and price advantages.
Our BDT-series processors are built to be operated by an operator and one assistant. Biodiesel Technologies, kolkata, India also offers custom automation systems that can be monitored from a single computer. Biodiesel Technologies, kolkata, India is committed to innovation, quality, and customer satisfaction. Let Biodiesel Technologies help you to start building your biodiesel processing facility of the future, today!
| Feature | Description | Competitive Edge |
| Chemical Adsorbent made by World's best chemical solutions group. | Chemical Adsorbent allows a waterless wash process with a zero toxic waste stream. Fuel produced is ultra dry and has a longer shelf life due to less oxidation and no exposure to water. | . Reduces oxidation from water contamination.
. Eliminates the need for water supply and Haz Mat disposal permits. . Eliminates wastewater treatment system, thus reducing initial cost and reoccurring plant power requirements. . Avoids EPA permitting issues. |
| Premixed Liquid Methylate available in the market | Catalyst and Methanol premixed together. | Does not require mixing methanol with caustic and provides better safety for personnel. |
| Modular System | Skid mounted modular design | Allows smallest -------- possible and provides the ability to add components. |
| Scalable System | Expandable capability up to the limitations of the model | Can easily scale your processing capacity to meet your requirements. |
| State of the Art Automation | . Touch screen controls
. Remote tank level monitoring |
Fully automated system with computer interface.r |
| Large Range of Processor Sizes | . 11,00 Lts . 1500 lts . 5000 lts . 10,000 lts . And above |
Ability to choose exactly the right size system for your specific requirements. Modular design allows for capacity up-grades. |
| Chemical Adsorbent purification towers (4) | Final filtration unit (.5 Micron) | Methanol recovery tank |
| Methanol recovery Condensor | All electrical power cabling | Touch screen control panel (Optional) |
| Variable speed multi motor control | All control wiring and cabling | All internal plumbing and piping |
| Settling tanks | Computer control module | Numerous metering valves |
| All Biodiesel Technocrats plumbing and electrical consoles | All Biodiesel Technocrats structural components for skids only | BDT -Catalytic Converts |
Process Description
The following is a step by step description of the Biodiesel Technologies process showing each step in the system and its purpose. Certain modules reflect choices of equipment that are driven by personal preference or choice of process.
The basic process for any catalyst induced transesterification process involoves migrating ester chains from a triglyceride molecule, and reconnecting the ester chains with a methanol or ethanol molecule, thus creating a methyl ester molecule. It is this methyl ester molecule that is Biodiesel. Various chemical and mechanical actions work together to make this trans-esterification occur. The catalyst used is a strong base, either sodium or potassium hydroxide. Once the ester chains are broken off, the left over glycerin molecule is a byproduct of the reaction. The mass balance is shown following this description.
• Raw materials holding tanks :
Storage tanks depicted in the upper left corner, hold the following supplies: The RED tank holds the alcohol (methanol or ethanol), the GREY tank holds the vegetable feedstock oil, (soy, rapeseed, etc.), The SILVER tank (optional) contains blending oil, (rendered fats, waste cooking oil, or other suitable material), the tank may also be used to store a secondary vegetable oil. The system can process two or more feedstocks of similar or dissimilar acid values. Combined acid value must be less than ≤ 5%. Acid value is an indicator for FFA (free fatty acid) level. FFA is approximately 50% of acid value. Product lost in the production process is about four times the FFA% with mixed feedstocks. RBD (Refined Bleached De-gummed) soy oil has no loss.
• Optional centrifuge and Blending Station :
As an option, Biodiesel Technologies processors can be fitted wit a blending module. Shown in the diagram as the yellow group just below the Feedstock 1 tank. The centrifuge, also optional, may be included with the blending skid offering further flexibility in feedstock selection. The blending unit simply blends and meters the various components together. The centrifuge separates water and other unwanted material from the incoming feedstock. For example, this combination would be used when working with a combination of soy and chicken fat.
• Catalyst Tank :
From the red methanol tank follow the line down to find the catalyst tank shown as a aqua coloured rectangle block just to the left of the Methanol/catalyst blending station. This tank is the bulk storage for the catalyst. Catalyst, also referred to as methoxide, can be either potassium, or sodium and are purchased in 30% (weight) solution with methanol forming a methylate. Using methlate is a safer, easier method of handling and blending catalyst into the process that does not require open mixing of methanol with the caustic. This method provides personal safety with economic benefits. Operators are not exposed to either methanol, or catalyst materials.
• Catalyst Mixing Station :
Just below the Red methanol tank is the methanol catalyst mixing station. It is at this station that the concentrated methoxide solution is blended with methanol to the exact proportions needed for the specific process recipe. Metering is done via closed loop control from the computer module. Process parameters and real time feedback are available on the computer control screen where operators can monitor flow rates at any given moment.
• Drying station #1 :
Water has been described as the bane of the Biodiesel industry. It causes soap to be formed in the transesterification process, and also causes the finished fuel to be unstable. The Biodiesel Technologies process in totally waterless, and to further deter any moisture contamination, Biodiesel Technologies uses two drying stations. The first drying station, depicted as a green box, following the line from the blending unit, re-circulates and heats the oil under vacuum to remove any residual moisture in the incoming feedstock. The second drying station, the methanol removal unit is discussed later in this document.
• Injection Stations :
Not shown on this block diagram are the injection stations that precisely meter and blend the methoxide mixture into the feedstock stream. These are located in the process where the violet catalyst line meets the black feedstock line, just above either transesterification reactor. Performance and status of injection modules are also computer controlled, and are graphically and numerically represented on the touch screen computer monitor.
• First Pass Transesterification Reactor :
Our system features a two stage transesterification process which accelerates conversion efficiency and maximizes yield. Approximately 80% of the feedstock oil is transesterified in the first pass. With other Biodiesel processes there is always a trade off between quality fuel and increased throughput. With the Biodiesel Technologies dual station transesterification process there is no trade off or sacrifice of fuel quality for throughput. The secrete involves the proprietary reaction tank design, and in the cutting of the fuel after the first transesterification reactor. The result is high throughput and high quality fuel.
• Glycerin Removal :
Depending upon process needs, initial separation of glycerin from product stream may be done using either a centrifuge or settling tanks or both. The combination of the two systems together makes for extremely high quality fuel.
If centrifuge, it would be located directly after the first reaction station is balanced to allow a slightly higher level of glycerin to remain in the biodiesel. Along with this glycerin is yet un-reacted feedstock and methanol. Allowing this small amount to continue on to the next reactor boosts the second reactor efficiency and yield. Glycerin is then pumped to the glycerin storage tank, shown in the upper right corner of the diagram. Glycerin contains approximately 1% methanol. This small amount helps to keep the glycerin liquid as ambient temperatures drop. The glycerin storage tank is the brown tank in the upper right corner of the illustration. Optionally, this step may represent settling tanks after the reactor, depending upon customer requests or process configuration.
• Second Injection Station :
Immediately after the glycerin removal station is the second catalyst injector. At this point a slightly different mixture of catalyst is carefully metered into to the process flow using proprietary metering nozzles. All metering is computer controlled. This station is similar to the previous injection station.
• 2nd Pass Transesterification Reactor :
The second pass reactor further pushes the reaction enabling the process to fully react any remaining mono, di, or triglycerides. More alcohol and a small amount of catalyst help to bias the reaction.
• Glycerin Removal :
Once again, depending upon process needs, separation of glycerin from product stream may be done using either a centrifuge or settling tanks or both. This decision would be made depending upon choice of feedstocks. The two systems make for an extremely versatile process.
If centrifuge is used, the second pass centrifuge is specifically tuned to cut the glycerin phase at a higher level, leaving a fraction of biodiesel in the glycerin. The leaves a cleaner biodiesel and while maintaining greater throughput. Trace amounts of biodiesel, methanol, and the remaining catalyst are carried away with the glycerin byproduct to the glycerin holding tank, shown as a dark green round tank in the upper right area of the diagram. Following the centrifuge, pumps move the product stream to the separation tanks.
Optionally, this step may represent settling tanks after second pass reactor, depending upon customer requests or process configuration.
• Methanol and Moisture Removal :
Following the glycerin removal, the product stream enters the methanol separation unit. This unit heats the oil to over 100 c while under vacuum. The oil then filters down over heated dispersion plates to facilitate removal of moisture and methanol. At this point again the stream branches and the biodiesel stream flows out the lower portion of the unit, and the vaporized methanol and are drawn off the top and into the methanol recovery unit. The ion exchange unit is discussed following methanol recovery unit.
• Methanol Recovery :
The distilled vapour from the methanol remove unit is vacuumed off and in to a methanol/water separator. Recovered methanol is then routed back to the main methanol storage unit. Any trace amounts of moisture recovered from the process is considered pure H2O and may be disposed of in the usual fashion. Approximately, 2% of the methanol introduced into the processor tanks is recovered. This represents approximately 100% of the free methanol in the biodiesel after process reactors.
• Chemical adsorbent activated Dry Wash :
Following methanol removal the biodiesel moves on the chemical exchange towers. One of the main reasons many customers choose the Biodiesel Technologies’ system is for the waterless wash. A unique active
Chemical adsorbent material specially produced is made work wonderfully with the Biodiesel Technologies processing systems. Our company has gone to such extents to create a purification system with this much experience behind it. The chemical adsorbent is a synthetic adsorbent looks very much like Sugargrounds and functions much like Sugar grounds in a percolator. The biodiesel fuel enters the top of the percolator and trickles down through the cylinder ofadsorbent. The active chemical adsorbent reacts with the unwanted material in the biodiesel. The resultant chemical reaction renders the material neutral, and it attaches itself to the Amberlite. The final product is pure and absolutely dry. The replacement Once its lifespan is over, It is neutral, and nontoxic. It is not a hazardous waste, and may be used a lindfill. It can be changed with out shutting down the process.
• Polish Filter :
The final polishing filter removes any extremely fine particulates that may have passed through the processor. Various grades of particulate filters are available. Filters are configured such that filter elements can be changed with out shutting down the process.
• Storage Tanks :
Following the final filtration, the biodiesel is ready for sale or storage. Typical parameters for storage require the fuel to be kept at temperatures above 38 degrees Fahrenheit. Biodiesel should not be stored from more than six month 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 any length of time in climates colder than 40° F.
Mass Balance Calculations :
The following table contains the mass balance for the Biodiesel Technologies transesterification process. All values are in weight as indicated. Potassium hydroxide (catalyst)
Input Kg.
Virgin Oil 1000
Potassium hydroxide (dry wt.) 9.3
Methanol 140
Total 1149.3
Output
Biodiesel 942.4
Glycerin + Impurities 206.9
Total 1149.3
