This is a newly designed, unique, fully continuous process technology for bio-diesel production. It works on multiple feedstocks in an economical way with the lowest utility consumption.
Bio-diesel plants have to go through various steps in the process; the first step is to prepare the raw material for trans-esterification. The new method of preparation will enhance the feed-stock choice and availability at a lower cost, as 65-70% of the cost of manufacturing bio-diesel is the raw material and 30-35% goes into processing. There are several methods used to prepare the feedstock for trans esterification.
Today, it is imperative to produce oil with low cost raw material to prepare as a feedstock for bio-diesel manufacturing and to get increased raw material availability as a feedstock. Some of the less expensive raw materials are lower grade waste oil, rendered animal fat, used cooking oil, sludge oil, trap grease and acid oil.
The current process is adopted for pre-treatment of oil with higher FFA during bio-diesel production.
- Caustic neutralization with wash.
- Thermal steam stripping
- Enzyme-catalyzed esterification
- Supercritical methanol esterification
- Acid esterification
Layer Esterification process is a technology newly developed by Mecpro and is the most cost effective method of converting waste oil as a feedstock for bio-diesel production.
Layer esterification is a process which converts the free fatty acids present in the oil to glycerides. This is done by adding glycerin to re-bond in a condensation process. In the trans –esterification process glycerin will be again separated and used for layer esterification.
Today, the bio-diesel industry uses many costly materials as feedstock such as palm oil, jatropha oil, rapeseed oil, sunflower oil and coconut oil though such oils are much more expensive than waste oil.
The trans-esterification process consists of the following steps, each of which has been designed by Mecpro to provide the highest level of performance with the least utility consumption.
The new hydro-cavitation mixing method will reduce the reaction time and number of steps for completing the trans-esterification. The reaction time for trans-esterification is less than half an hour, with single stage operation and less methanol intake into the process. Compared to the multi stage reaction process adopted in most bio-diesel projects this helps in increasing the degree of esterification and will reduce the utility consumption significantly since methanol intake is much less than in the conventional process.
The system is made in such a way that the glycerin and soap will be separated. To ease the de-methylation and water wash and to perform the process effectively all previous steps ensure that excess soap formation and emulsification does not occur.
A three stage demethylation system using the falling film principle, along with a low density separator effectively enhances the separation of methanol. So methanol loss in the wash water will be significantly reduced and the utility consumption is lowered.
The continuous wash water system will remove all impurities effectively with the remaining moisture content being less than 1000 PPM. Hence this reduces steam consumption in the drying section.
The newly designed distillation section for liquid to vapour and liquid to liquid distillation, with steam generation at 3 kg/cm2 pressure will help to reduce the heat energy consumption significantly.
The continuous process of glycerin de-methylation, acidulation, and salt separation will enhance the quality of glycerin as well as reduce utility consumption. Besides, the process will facilitate the usage of NaOH as catalyst to reduce the cost of production.
We have the facilities and capability, besides vast experience, to provide a full range of technical support to set up a bio-diesel plant.
We are committed to the highest level of sustainable operations using our process technologies, by providing alternative energy solutions to the industry. This is made possible through an efficient fuel developed with products that are readily available in the current environment in order to serve the energy demands of today’s world.
PROCESS TECHNOLOGY FOR LAYER ESTERIFICATION IN BIO DIESEL PLANT
The Crude Oil CPO, sludge oil and waste vegetable oil obtained from phosphatides and decomposed products sediments is moisture treated with phosphoric acid into the conditioned form to be taken out along with clay. The oil is pumped to the feed tank from the storage tank and the low-high level controls the feed pump as required. The desired temperature will be increased with the economization of the outlet product in the PHE.
PHE will compensate for the heat required in the process during start up and processing. Then oil and water are mixed in the static mixer and retained in the hydration tank for proper conditioning. After conditioning the oil is fed to the bleaching section.
CONTINUOUS TWIN BLEACHING SECTION
The dryer cum bleacher will remove the moisture in a thin film effectively. The spent bleaching earth will be dozed in a closed circuit from the cyclonic filter to remove the impurities and to prevent the inactivation of fresh bleaching earth in the second bleacher. Fresh bleaching earth will be dozed in the oil as per the process requirement and pumped to the Pressure Leaf filter through the cyclonic filter.
LAYER ESTERIFICATION OF HIGHER FFA OIL (PATENTED)
The PFAD or bleached oil is pumped to the detoxifier and passed through a glycerol scrubber to the MAC 3 column where the deaerated glycerin is added in a layer form to the oil to eliminate any reaction with the glycerides present in the oil. The glycerin or fatty acid escaped in the reaction process will be entrapped with the glycerol scrubber, trap condenser and fatty scrubber and fed back to the Layer-esterifier automatically. The dozing of glycerin is controlled by the flow signal and the set value entered into the ratio controller. The excess glycerin will be taken back to the packed column along with the fatty acid. The density separator will ensure that the FFA reduction is to the desired level. Thereafter the oil will be decomposed, deodorized and discharged to the final storage tank.
- Flexible scale of Operation
- Mode: Continuous process
- Feedstock: - Refined or Crude Vegetable oils and Animal Fats, Grease, Waste Oils, Used Cooking Oils, Sludge oil, Acid oil etc.
- New process technology
- Lower methanol consumption
- Lower methanol rectification load
- Lower utility consumption
- Fully automated
- Higher product yield
- Superior product quality
- Better yield and quality of co-products
The above technology will produce distilled fatty acid with overall yield > 98%, with the product quality confirming to EN 14214 and ASTM D6751 specifications.