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1. Valves 4 and 6 can be shut and the mixture of oil and methoxide allowed to settle for 8 hours NOTE User should visually inspect the surface of the fluid in the mixing tank If there is a foamy light colored layer on the surface user should stir to break up the layer This will ensure complete reaction After the settling time user should be able to see through the tank wall a distinct line of separation near the bottom of the tank where the denser glycerin has settled to the bottom and the Biodiesel is left on top Valves 2 and 6 are opened to allow only the glycerin to drain into the waste discharge container Valve 6 should be shut as soon as the glycerin drains out completely and the discharge changes to a noticeably lighter color Biodiesel then primes the magnetic drive pump Valve 7 is opened and the pump turned on This pumps the fuel through the filter and into a storage tank Once the mixing tank has completely drained the pump is turned off and the excess fuel in the line drained All valves are then closed Biodiesel should be kept in air tight containers in a cool place and is ready to use 5 2 Automated Steps Once the raw materials have been added in the appropriate manner the system is ready to be initiated Follow the steps below referencing the pictures in Section 8 5 1 Powering the PLC In order to power the PLC first plug in the machine and then push the red pushbutton located above the Emergency Stop
2. 2003 2004 8 APPENDIX 8 1 Oil Yields c litres lbs TOP oil ha oil acre gal acre corn maize cashew nut 148 oats 183 lupine 9 kenaf calendula cotton hemp soybean 4 coffee linseed flax hazelnuts S Es BIO Oju 5 E E 5 3 euphorbia pumpkin seed S F Ko S an o coriander S oo 4 4 mustard seed 4 camelina 4 sesame 5 safflower 7 e ES O a Ni nije i o o Aala o 2 2 2 3 3 3 8 9 NO o US 18 19 23 25 29 33 35 39 48 49 51 51 56 57 57 61 62 74 83 88 100 102 24 27 29 91 94 02 40 55 MC 2 tung oil tree sunflowers cocoa cacao 863 110 peanuts opium poppy 978 rapeseed 0 olives 1019 castor beans 1188 151 pecan nuts 1505 jojoba 1528 jatropha macadamia nuts 1887 brazil nuts 2010 2 avocado coconut oil palm i tml ound at http www journeytoforever org biodiesel_yield h oo o o 113 1 1 1 1 1 2 2 Production of Biodiesel Senior Engineering User s Manual 2003 2004 8 2 Oil and Ester Characteristics Oils and esters characteristics Melting Range deg C Iodine Cetane Oil Methyl Ethyl number number Type of Oil Fat Ester Ester Rapeseed oil h eruc 2 97 to 105 Rapeseed oil i eruc 10 12 110 to 115 Sunflower oil 18 12 125 to 135 Olive oil 12 6 8 77t094 Soybean oil 12 12 53 Cotton seed oil s 100 to 115 55 Corn oil 10 12 53 Coconutoil 2
3. 13 2003 2004 Storing the Biodiesel Stopping the Process Production of Biodiesel Senior Engineering User s Manual 2003 2004 14
4. 0t024 o 6 swi0 Palm kerneloil 201026 s t2tots Palm oil 65 Palm oleine 65 Palm stearine 85 Tallow 15 Lard Found at http www journeytoforever org biodiesel_yield html Production of Biodiesel Senior Engineering User s Manual 2003 2004 8 3 System Diagram Heating Tank 7 5 Micron Filter Storage Magnetic Tank N Drive Pump on 6 Methoxide Tank Waste Discharge Circulation Pump El Production of Biodiesel Senior Engineering User s Manual 10 2003 2004 8 4 Process Diagram 5 Micron Storage Tank Magnetic Drive Pump Methoxide Tank Discharge Om v Circulati Ys Pump Initial Setup 5 Micron Storage Tank Magnetic Drive Pump Methoxide Tank Discharge Les ulation Circu m voe P ump Heating and Methoxide Circulation Heating Tank 5 Micron Filter Magnetic Drive Pump Storage Tank Methoxide Tank 5 Micron Filter Storage Tank Magnetic Drive Pump Methoxide Tank Waste Discharge Circulatios OE voe Pump Z Circulating Heated Oil 5 Micron Filter Storage Tank Magnetic Drive Pump Methoxide Q Tank Waste Discharge Circulation On va Pamp Addition of Methoxide to Circulating Heated Oil 5 Micron Filter Mixing Tank Storage Tank Magnetic Drive Pump Methoxide Tank Waste Waste Discharge Disc
5. ENGR 491 SENIOR DESIGN PROJECT Biodiesel User s Manual 2003 2004 Messiah College Department of Engineering Brandon Apple Jon Bitterman Becky Gast Kyle McNamara Mike Mullen Tamika Pinkney TABLE OF CONTENTS eN E Go Ne on Introduction Adding Oil to The SEM a Rect Sc eet gta Rig tee eet et Adding Methanol and Lye 5 2 Automated Steps O Rc ga A A eR Ee ee GAY F 01862 141 A A IO OO O phe sas Sey SOON ION SO A A E A RENO 8 2 Oil and Ester Characteristics eee 8 3 System Diagram 8 4 Process Diagram 8 4 Control Board Production of Biodiesel Senior Engineering User s Manual 2003 2004 00 J J30 UU HAH W WW WW Rh me ODO Ww 1 INTRODUCTION The Production of Biodiesel senior project team created a versatile system for converting cooking oil into usable fuel for diesel vehicles The system can accept a variety of vegetable based oils and can produce a range of batch sizes With the work in automation of the E Biodiesel senior project team the system can produce batches with little user input 2 INGREDIENTS 2 1 Oil Biodiesel can be produced out of a variety of natural products Every oil will require differing amounts of chemicals for reaction and will produce a fuel with slightly differing qualities Section 8 1 contains information on approximate fuel yields of many agricultural products and Section 8 2 gives information on the oil and ester characteristics of these produc
6. f the oil that is going to be input to the system The titration determines the fatty free acid content of the oil by indicating its pH If available a digital pH meter could eliminate the titration or litmus paper could be used as well Below is a set of basic instructions for the titration If more detailed instructions are needed visit http www journeytoforever org biodiesel_mike html Titration Steps See Section 8 3 for pictures Weigh out gram of cooking oil into an Erlenmeyer flask Add 10 mL of Isopropyl Alcohol to the oil sample and mix vigorously Add one packet of phenolphthalein to the mixture and mix vigorously Fill buret with 0 1 M Sodium Hydroxide and record initial volume Titrate the sample with the Sodium Hydroxide until mixture changes color and color remains 6 Record final volume of Sodium Hydroxide in buret E a Production of Biodiesel Senior Engineering User s Manual 4 2003 2004 Lye Calculation Add 3 5 to the number of milliliters of sodium hydroxide used to titrate the oil if you are using waste cooking oil Do not add the 3 5 if you are using fresh cooking oil This is the number of grams of lye needed to be added into the system for every liter of oil added into the system For example if the number of milliliters of sodium hydroxide was 2 then 5 5 grams of lye would be needed for every liter of waste cooking oil Methanol Calculation For every gallon of oil added to the system 1 5 of a gall
7. harge tn Circulatio Om v crak Om vo Pump Draining Heated Oil Circulating Oil Methoxide Mixture Production of Biodiesel Senior Engineering User s Manual 11 2003 2004 Heating Tank 5 Micron Filter Magnetic Drive Pump Methoxide Tank Waste Discharge Circulation OE vano Pump J Settling of Oil Methoxide Mixture Heating Tank 5 Micron Filter Storage Tank Magnetic Drive Pump Methoxide Tank Waste Discharge GM var Pump Fully Settled Biodiesel and Glycerin Heating Tank 5 Micron Filter Storage Tank Magnetic Drive Pump Waste Methoxide Tank Discharge La 7 OE voe Cireutacion ump Draining Glycerin Production of Biodiesel Senior Engineering User s Manual 2003 2004 5 Micron Filter Mixing Q Tank O Magnetic Y Drive Pump Methoxide Tank Storage Tank Waste Discharge F4 Circulation OE voe Pump fF Glycerin Fully Drained Storage Magnetic d Tank Drive Pump Waste Discharge Methoxide Tank Circulation O vv Pump 4 Pumping Biodiesel to Storage Tank 5 Micron Filter Storage Tank Magnetic Drive Pump Methoxide Tank Waste Discharge Om voe pr ump Completed Process 8 5 Control Board Starting the Process Mixing Cycle Draining the Glycerin Production of Biodiesel Senior Engineering User s Manual
8. l is being used often there can be particles of food in the oil that could clog the system or cause damage to the pumps Our team used a window screen attached to a metal ring could be fitted to 15 gallon steel tanks While the oil was still warm we poured the liquid oil through the filter and into a storage transportation tank From this tank the oil could be measured out and poured into the heating tank of our system after ensuring that the valve on the bottom of the tank is closed NOTE 3 gallons is the minimum batch of oil that can be used to ensure that both immersion heaters are fully covered and that the pump will be primed 4 ADDING METHANOL AND LYE TO THE SYSTEM WARNING Both methanol and lye are potentially harmful substances Methanol methyl alcohol is a skin irritant as well as harmful if swallowed The fumes from the methanol should not be inhaled so handle in a well ventilated area Lye also called sodium hydroxide or caustic soda is a caustic base that should not be ingested or come in contact with skin If contact with skin should occur vinegar can be used to rinse neutralizing the base Once the methanol and lye are mixed methoxide is produced This substance is harmful if touched ingested inhaled or if fumes come in contact with eyes Safety equipment must be used including appropriate eye wear gloves and respiratory mask To determine how much lye needs to be used a titration should be performed on a sample o
9. on of methanol must be added to the system So for a 3 gallon batch of oil 3 5 of a gallon of methanol must be used Once the amounts of the lye and methanol have been determined both are ready to be input to the system Ensuring that valve 5 see Section 8 3 is closed the methanol can be poured into the methoxide tank first Then the lye can be added to the methoxide tank Once the two are in the tank the lid should be screwed on 5 OPERATION 5 1 Manual Steps NOTE If the processor is set up for automated use skip these manual steps and follow the automated instructions Once the raw materials have been added in the appropriate manner the system is ready to be initiated Follow the steps below referencing the diagrams in Section 8 3 and Section 8 4 All valves are initially closed and heaters and pumps turned off 1 Turn on the immersion heaters in the heating tank The target temperature is between 50 60 degrees Celsius Some stirring of the oil will ensure an even temperature distribution and speed the heating process but it is not necessary 2 While the oil is heating the methanol and lye can begin to circulate Turn on the methoxide circulation pump The methanol and lye will circulate with turbulence creating a methoxide solution There is no set length of time to circulate the methoxide but ensure that the lye has been fully dissolved into the methanol 3 Once the oil is heated and the lye fully dissolved the ci
10. rculation pump can be turned off 4 Valve 1 is opened draining the oil into the mixing tank After the oil has fully drained valve 1 is closed and valves 2 and 4 are opened The magnetic drive pump is then initiated circulating the oil 5 As the oil circulates valves 3 and 5 are opened allowing the methoxide to drain into the circulating line by force of gravity User should be aware that there is a manual Production of Biodiesel Senior Engineering User s Manual 5 2003 2004 10 11 12 13 valve directly beside valve 3 that acts as a flow limiter The manual valve should be just slightly open to allow a slow feed of the methoxide into the circulation line As the methoxide tank and line drain completely valves 3 and 5 should be shut to stop air from being pulled into the oil circulation line Once the methoxide is completely drained into the system the circulation through the magnetic drive pump should be continued for an hour to ensure a thorough mixture After the mixing valve 2 is shut and valve 6 opened in rapid succession As soon as air begins to be sucked into the magnetic drive pump the pump needs to be shut off This rapid progression allows the oil that is in the line between valve 2 and the pump to be pulled up to the pump before it is shut off allowing more oil to be pushed into the mixing tank Once the pump is turned off the excess oil in the line is pushed by gravity into the waste discharge container
11. sign You should hear a click from the relay indicating that power is being supplied to the PLC 2 Starting the Process To start the oil heating and methoxide mixing processes you need to push the Manual Start pushbutton As soon as the pushbutton is pushed the mimic board should look just as it does in the picture If this does not occur there is something wrong with the wiring Consult the electrical drawings for further help Production of Biodiesel Senior Engineering User s Manual 6 2003 2004 3 Mixing Cycle The mixing cycle should start immediately after a 15 minute duration The mimic board should appear as in the picture If this does not occur there is something wrong with the wiring Consult the electrical drawings for further help Also the LED labeled Valve 1 should stay lit for the rest of the process 4 Draining the Glycerin When the Biodiesel has settled for eight hours the process should automatically alert you to drain the glycerin When this occurs you should push in the pushbutton above the alert LED until you are satisfied that all the glycerin is released from the mixing tank Pushing the button multiple times will not interrupt the sequence but do not push the button once the switch has been turned to store the Biodiesel 5 Storing the Biodiesel As soon as you release the glycerin pushbutton the LED to alert you to begin storing should come on To start the storing process simply turn the switch
12. to the right and the mimic board should appear as in the picture Valve one should close at this time 6 Stopping the Process To stop the process simply turn the store Biodiesel switch back to the left and push the mushroom pushbutton in 7 Emergency Stop To stop the program in an emergency push in the mushroom pushbutton To restart the process turn the mushroom pushbutton to the right and pull out Then push the red pushbutton 6 CLEANING 1 Allow contents in line to be gravity fed to waste container 2 If possible use airline to blow contents in line out into waste container 3 4 If the system is going to be unused for awhile run system with soapy water to clean oil from tanks and lines Make sure system is fully dry before making next batch of Biodiesel 7 MAINTENACE 1 A ON Oe NS The filter will need to be changed if there is not a distinct color change between the incoming and outgoing Biodiesel or if the pump has difficulty pushing Biodiesel through the filter Filters can be washed dried and reused Check the seals of the valves and pumps for corrosion Check holes and seals on tanks for leaks Check heating tank for rust Check for kinked hose or blockage of lines Check electrical wiring for wear or breaks Check methoxide tank for residual lye Check bottom of heating tank for sedimentation that needs to be cleaned out Production of Biodiesel Senior Engineering User s Manual 7
13. ts Virgin oil can be used as well as waste oil Typically virgin oils require smaller amounts of the reactants to produce quality fuel However the purpose of this project was to enable waste cooking oil to be recycled into usable fuel This will require a higher cost for the amount of chemicals needed but will probably result in saving the user money since waste cooking oil is readily available for no cost at many dining facilities 2 2 Methanol Methanol methyl alcohol is a common fuel used in auto racing It can be found at many gas stations located near racing tracks especially tracks where private owners are allowed to race The methanol must be 99 9 pure for the reaction to be complete The racing fuel is often not labeled with purity but rather on a grading system Grade A virgin methanol has a high enough purity to ensure the reaction 2 3 Lye Lye also referred to as sodium hydroxide or caustic soda can be found in reagent grade at chemical stores or more commonly as drain cleaner in grocery stores The lye should be at least 95 pure Red Devil brand lye is 99 pure and readily available In storing and using the lye air tight containers should be used since lye absorbs humidity in the air Production of Biodiesel Senior Engineering User s Manual 3 2003 2004 3 ADDING OIL TO THE SYSTEM Before the oil can be added to the system 1t should be filtered for any large sediment that may be in the oil If waste cooking oi

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