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Title:
METHOD OF PREPARATION OF BIODIESEL AND APPARATUS THEREFOR
Document Type and Number:
WIPO Patent Application WO/2018/083576
Kind Code:
A1
Abstract:
A method and an apparatus to produce biodiesel with high yield and purity is disclosed. The apparatus employing the method includes a methanol reactor tank to mix an acidic catalyst with methanol for carrying out processes subsequent. The mixture is transferred to an acid reactor tank in which vegetable oil is introduced and esterification carried out. The esterified oil is next transferred to a base reactor tank that receives methanol and a basic catalyst from the methanol reactor tank. Transesterification /neutralization of the esterified oil is carried out therein to produce biodiesel that is further purified using dry washing. Glycerine produced in acid reactor tank and base reactor tank is allowed to settle and decanted, while methanol in both the tanks is recovered using heat exchangers and recycled. Fluid transfer from one tank to another is achieved using gravity. The apparatus is mounted on a portable trolley and so is capable of quickly being relocated as needed.

Inventors:
NAYAK SWARUP KUMAR (IN)
MISHRA PURNA CHANDRA (IN)
Application Number:
PCT/IB2017/056707
Publication Date:
May 11, 2018
Filing Date:
October 28, 2017
Export Citation:
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Assignee:
NAYAK SWARUP KUMAR (IN)
MISHRA PURNA CHANDRA (IN)
International Classes:
C11C3/00
Domestic Patent References:
WO2008111915A12008-09-18
Foreign References:
US4164506A1979-08-14
US20080040970A12008-02-21
Attorney, Agent or Firm:
KHURANA & KHURANA, ADVOCATES & IP ATTORNEYS (IN)
Download PDF:
Claims:
We Claim:

1. A method for preparation of a biodiesel, the method comprising the step of: effecting esterification of a vegetable oil with at least one lower aliphatic alcohol in presence of a first catalyst, characterized in that, the esterified vegetable oil is subjected to neutralization in presence of a combination of a second catalyst and an excess of the at least one aliphatic alcohol, with proviso that,

when the first catalyst is acidic in nature, the second catalyst is basic in nature and

when the first catalyst is basic in nature, the second catalyst is acidic in nature.

2. The method as claimed in claim 1, wherein the method further comprises the step of degumming to effect removal of wax like substances from the vegetable oil prior to effecting esterification thereof.

3. The method as claimed in claim 1, wherein the at least one lower aliphatic alcohol is selected from the group consisting of methanol, ethanol , propanol and butanol.

4. The method as claimed in claim 1, wherein the method further comprises the step of effecting recovery of the at least one lower aliphatic alcohol.

5. The method as claimed in claim 1, wherein the method further comprises the step of effecting dry washing of the biodiesel.

6. The method as claimed in claim 5, wherein the step of dry washing is effected using any or a combination of ion exchange resin column and magnesol based column.

7. The method as claimed in claim 1, wherein the vegetable oil comprises non-edible straight chain vegetable oil.

8. An apparatus for production of biodiesel, the apparatus comprising:

a first reactor configured to hold a reaction mixture comprising a vegetable oil, at least one lower aliphatic alcohol and a first catalyst to effect esterification of said vegetable oil; and

a second reactor configured to hold the esterified vegetable oil, the at least one lower aliphatic alcohol and a second catalyst to effect neutralization of said esterified vegetable oil,

wherein the first reactor is configured to transfer the esterified vegetable oil to the second reactor for effecting neutralization thereof in presence of an excess of the at least one lower aliphatic alcohol.

9. The apparatus of claim 8, wherein the apparatus further comprises at least one heat exchanger configured to effect recovery of the at least one lower aliphatic alcohol.

10. The apparatus of claim 8, wherein the apparatus further comprises any or a combination of ion exchange resin column and magnesol based column to effect dry washing of the biodiesel.

Description:
METHOD OF PREPARATION OF BIODIESEL AND APPARATUS THEREFOR

TECHNICAL FIELD

[0001] The present disclosures relates to the field of biofuels. More particularly, the present disclosures relates to an apparatus and a method for manufacturing biodiesel.

BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] A biofuel is a fuel that is produced through contemporary biological processes, such as agriculture and anaerobic digestion, rather than a fuel produced by geological processes such as those involved in the formation of fossil fuels, such as coal and petroleum, from prehistoric biological matter. Biofuels can be derived directly from plants, or indirectly from agricultural, commercial, domestic, and/or industrial wastes

[0004] Biodiesel is a biofuel comprised of mono-alkyl esters of long chain fatty acids derived from vegetable oils or animal fats, designated B 100, and meeting the requirements of ASTM D 6751. It is a renewable, clean-burning diesel replacement that is reducing dependence on petroleum, creating jobs and improving the environment. Made from a diverse mix of feed stocks including recycled cooking oil, soybean oil, and animal fats, it is the first and only EPA-designated Advanced Biofuel in commercial-scale production across the US and the first to reach 1 billion gallons of annual production in the US. Meeting strict technical fuel quality and engine performance specifications, it can be used in existing diesel engines without their modification and is covered by all major engine manufacturers' warranties.

[0005] The production of biodiesel requires an esterification process. In the process, a triglyceride is made to undergo a reaction with an alcohol to form esters and glycerine. A triglyceride has a glycerine molecule as its base with three long chain fatty acids attached. The characteristics of the fat are determined by the nature of the fatty acids attached to the glycerine. The nature of the fatty acid can in turn affect the characteristics of the biofuel. During the process, the triglyceride is reacted with alcohol in the presence of a catalyst, usually a strong alkali like sodium hydroxide. The alcohol reacts with the fatty acid to form the mono-alkyl ester (biodiesel), and crude glycerine. In most of the production methods, methanol is the alcohol used and so, methanol produces methyl-ester and ethanol produces ethyl-esters. The catalyst used is either potassium hydroxide or sodium hydroxide. Potassium hydroxide has been found to be more suitable for the ethyl ester production. The process of esterification is carried out in a mixing apparatus known as a biodiesel reactor.

[0006] However, present biodiesel production methods and apparatus that employ the esterification process cannot produce high quality fuels (for instance, fuels according to related standards such as EN 4214 and ASTM D6751). Hence a further purification step is necessary.

[0007] Additionally, present biodiesel production apparatuses are time consuming, cumbersome and require a high level of skill to be operated and generate biodiesel with low yield. Besides they don't have a system of regenerating methanol that is used up in them.

[0008] Hence there is a need in the art for a biodiesel production apparatus that gives a high yield and purity of biodiesel is simple to operate and maintain and does not waste methanol.

[0009] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0010] In some embodiments, the numbers expressing quantities or dimensions of items, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term "about." Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0011] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0012] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.

OBJECTS OF THE INVENTION

[0013] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[0014] It is an object of the present disclosure to provide for a biodiesel production apparatus that produces biodiesel to international standards.

[0015] It is an object of the present disclosure to provide for a biodiesel production apparatus that does not waste methanol.

[0016] It is an object of the present disclosure to provide for a biodiesel production apparatus that is fast and easy to operate, and has a high biodiesel yield.

[0017] It is an object of the present disclosure to provide for a biodiesel production apparatus that has lower manufacturing cost, material cost and operating cost.

SUMMARY

[0018] This summary is provided to introduce a selection of concepts in a simplified form to be further described below in the Detailed Description. This summary is not intended to identity key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. [0019] The present disclosure relates to an apparatus and a method for manufacturing biodiesel wherein biodiesel of high quality can be produced in a fast, easy and economical manner.

[0020] In an aspect, present disclosure describes a method for preparation of a biodiesel, the method including the step of: effecting esterification of a vegetable oil with at least one lower aliphatic alcohol in presence of a first catalyst, characterized in that, the esterified vegetable oil is subjected to neutralization in presence of a combination of a second catalyst and an excess of the at least one aliphatic alcohol, with proviso that, when the first catalyst is acidic in nature, the second catalyst is basic in nature and when the first catalyst is basic in nature, the second catalyst is acidic in nature.

[0021] In another aspect, the method can further include a step of degumming to effect removal of wax like substances from the vegetable oil prior to effecting esterification thereof.

[0022] In yet another aspect, the at least one lower aliphatic alcohol can be selected from the group consisting of methanol, ethanol, propanol and butanol.

[0023] In another aspect, the method can further include a step of effecting recovery of the at least one lower aliphatic alcohol.

[0024] In yet another aspect, the method can further include a step of effecting dry washing of the biodiesel.

[0025] In an aspect, the step of dry washing can be effected using any or a combination of ion exchange resin column and magnesol based column.

[0026] In another aspect, the vegetable oil can include non-edible straight chain vegetable oil.

[0027] In an aspect, present disclosure elaborates upon an apparatus for production of biodiesel, the apparatus including a first reactor configured to hold a reaction mixture comprising a vegetable oil, at least one lower aliphatic alcohol and a first catalyst to effect esterification of the vegetable oil; and a second reactor configured to hold the esterified vegetable oil, the at least one lower aliphatic alcohol and a second catalyst to effect neutralization of the esterified vegetable oil, wherein the first reactor can be configured to transfer the esterified vegetable oil to the second reactor for effecting neutralization thereof in presence of an excess of the at least one lower aliphatic alcohol.

[0028] In another aspect, the apparatus can further include at least one heat exchanger configured to effect recovery of the at least one lower aliphatic alcohol.

[0029] In yet another aspect, the apparatus can further include any or a combination of ion exchange resin column and magnesol based column to effect drywashing of the biodiesel. [0030] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features.

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0032] The diagrams are for illustration only, which thus is not a limitation of the present disclosure, and wherein:

[0033] FIG. 1 illustrates a portable biodiesel production apparatus, in accordance with an exemplary embodiment of the present disclosure.

[0034] FIG. 2 illustrates by means of a block diagram the functioning of a portable biodiesel production apparatus, in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION

[0035] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0036] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0037] If the specification states a component or feature "may", "can", "could", or "might" be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0038] As used in the description herein and throughout the claims that follow, the meaning of "a," "an," and "the" includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of "in" includes "in" and "on" unless the context clearly dictates otherwise.

[0039] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.

[0040] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this invention. Those of ordinary skill in the art further understand that the exemplary apparatus, processes, methods and the like described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named element.

[0041] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims. [0042] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., "such as") provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0043] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0044] The present disclosure relates to an apparatus and a method for manufacturing biodiesel wherein biodiesel of high quality can be produced in a fast, easy and economical manner.

[0045] In an aspect, present disclosure describes a method for preparation of a biodiesel, the method including the step of: effecting esterification of a vegetable oil with at least one lower aliphatic alcohol in presence of a first catalyst, characterized in that, the esterified vegetable oil is subjected to neutralization in presence of a combination of a second catalyst and an excess of the at least one aliphatic alcohol, with proviso that, when the first catalyst is acidic in nature, the second catalyst is basic in nature and when the first catalyst is basic in nature, the second catalyst is acidic in nature.

[0046] In another aspect, the method can further include a step of degumming to effect removal of wax like substances from the vegetable oil prior to effecting esterification thereof.

[0047] In yet another aspect, the at least one lower aliphatic alcohol can be selected from the group consisting of methanol, ethanol, propanol and butanol.

[0048] In another aspect, the method can further include a step of effecting recovery of the at least one lower aliphatic alcohol.

[0049] In yet another aspect, the method can further include a step of effecting dry washing of the biodiesel.

[0050] In an aspect, the step of dry washing can be effected using any or a combination of ion exchange resin column and magnesol based column.

[0051] In another aspect, the vegetable oil can include non-edible straight chain vegetable oil. [0052] In an aspect, present disclosure elaborates upon an apparatus for production of biodiesel, the apparatus including a first reactor configured to hold a reaction mixture comprising a vegetable oil, at least one lower aliphatic alcohol and a first catalyst to effect esterification of the vegetable oil; and a second reactor configured to hold the esterified vegetable oil, the at least one lower aliphatic alcohol and a second catalyst to effect neutralization of the esterified vegetable oil, wherein the first reactor can be configured to transfer the esterified vegetable oil to the second reactor for effecting neutralization thereof in presence of an excess of the at least one lower aliphatic alcohol.

[0053] In another aspect, the apparatus can further include at least one heat exchanger configured to effect recovery of the at least one lower aliphatic alcohol.

[0054] In yet another aspect, the apparatus can further include any or a combination of ion exchange resin column and magnesol based column to effect drywashing of the biodiesel.

[0055] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features.

[0056] In an aspect, present invention relates to an apparatus and a method for batch preparation of biodiesel from various non-edible straight vegetable oils. Biodiesel so produced can be used for many commercial purposes.

[0057] In another aspect, invention disclosed is a portable biodiesel production apparatus ( interchangeably termed as a biodiesel reactor or reactor herein ) that can effect increase in biodiesel yield percentage and methanol recovery, reduction in separation time of glycerine and production of pure biodiesel; and is capable of quickly being relocated as needed.

[0058] In another aspect, reactor disclosed can include a batch type Stirred Tank Reactor (STR) that can provide for more efficient mixing. In an exemplary embodiment, STR can have a capacity of 5 liters.

[0059] In yet another aspect, invention disclosed can use an ion exchange resin column and magnesium silicate powder (Magnesol) as filter aids to further purify crude bio diesel produced to international standards such as ASTM D 6751. This novel process can be termed Dry Washing.

[0060] In another aspect, the reactor can include a distillation method employing tubular heat exchanger to improve purity of methanol regenerated in the apparatus and enable its repeated use. [0061] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features.

[0062] FIG. 1 illustrates a portable biodiesel production apparatus, in accordance with an exemplary embodiment of the present disclosure.

[0063] In an aspect, portable biodiesel production apparatus (interchangeably termed as a biodiesel reactor or reactor herein) disclosed can consist of a solid base with wheels attached. Various sub-components of the reactor can be configured and affixed onto this solid base in such a fashion that the whole reactor is very stable on the solid base and yet can be easily transported using wheels attached.

[0064] In an exemplary embodiment, the reactor can include, amongst others, a portable trolley base 102 with wheels 104, a methanol reactor tank 106, an acid reactor tank 108, a base reactor tank 110, a heating mantle, static mixerl50 with motor for all the three reactor tanks, a methanol recovery system (128 and 130), a dry washing system and associated pipes, funnels and stopcocks etc. as shown in FIG. 1 and elaborated herein.

Portable Trolley Base 102 with wheels 104

[0065] In an aspect, various components of reactor disclosed can be affixed on trolley base 102 that can have a flat bed/base with wheels underneath. Such a base can enable the whole reactor to be moved easily from one place to another, thereby making it a mobile biodiesel production unit.

[0066] In an exemplary embodiment, the dimensions of trolley base 102 can be of dimensions approximately 1500X1100 mm, while the total height of reactor disclosed can be 1720 mm.

[0067] In another exemplary embodiment, wheels 104 can be of diameter 137.05 mm and can be attached to a bracket of dimension 125. 35 mm and 76 mm having thickness of 2mm with help of a spindle pin arrangement. The spindle pin can be next welded to trolley bottom at its four different corners. In this fashion, trolley base 102 can have wheels 104 affixed at its bottom to enable its easy movement.

[0068] In an aspect, trolley base 102 can have on it three stands at three different heights onto which three tanks can be mounted. The tanks can be further connected with appropriate pipes as elaborated hereunder. The three stands, three tanks and associated pipes etc. can together comprise the batch type stirred tank reactor (STR). In another aspect, for increased stability, the three stands can be configured to be equidistant from each other. The mounting plate of the stands can have holes configured in them to enable liquid collected at bottom of tanks mounted on them to be decanted off, as elaborated further.

[0069] In an exemplary embodiment, trolley base 102 can have stand 148a at a height of 1380 mm from its base. Stand 148a can have a methanol reactor tank 106 mounted on it. Likewise stand 148b at a height of 850 mm can have an acid reactor tank 108 on it while stand 148c can be at a height of 400 mm and have base reactor tank 110 mounted on it. In another exemplary embodiment, for a 5 liter capacity multiple tank STR apparatus, each of the tanks can have a capacity/volume of 5 liters.

[0070] From the configuration as elaborated above, it can readily be understood that methanol reactor tank 106 is highest, followed by acid reactor tank 108 and then base reactor tank 110 which is the lowest. Pipes can be so configured amongst these tanks so that liquid contents of a tank can flow into a tank lower than it, as elaborated further.

[0071] In an exemplary embodiment, in order to make the stands more rigid all the four corners of the stand can be held fixed on trolley base 102 using 4 square bars of cross-section 20mm X 20mm, with thickness of 2mm. Additional support can be given by using cross- linked bars.

Methanol reactor tank 106

[0072] In an aspect, methanol reactor tank 106 can be a borosil glass flask. In an exemplary embodiment, methanol reactor tank 106 can be of a semi-spherical profile with outer diameter 228 mm, internal diameter 220 mm, and height of 312 mm.

[0073] As elaborated above, in an exemplary embodiment, methanol reactor tank 106 can be mounted on stand 148a at a height of 1380 mm above portable trolley base 102. Liquid mixture in methanol reactor tank 106 can flow out from its bottom to other containers below it via gravity using a non-pressurized gravitational flow method.

[0074] In an aspect, methanol reactor tank 106 can be configured with means on its top surface to receive liquids as required. In an exemplary embodiment, methanol reactor tank 106 can be configured with at least one funnel on its top surface shown as 112 to introduce chemicals in methanol reactor tank 106. In an exemplary embodiment, funnel 112 can be of 26 mm external diameter and 18 mm internal diameter. In alternate exemplary embodiments, there can be more than one funnels, as required.

[0075] In yet another aspect, methanol reactor tank 106 can have at its bottom means to discharge its liquid contents either to base reactor tank 110 or to acid reactor tank 108. In an exemplary embodiment, such means can include a two way stop cock shown as 114 wherein one connection 116a of two way stop cock 114 can transfer contents of methanol reactor tank 106 to base reactor tank 110 via pipe 134a and other connection 116b of two way stop cock 114 can transfer contents of methanol reactor tank 106 to acid reactor tank 108 via pipe 134b.

[0076] In an exemplary embodiment being elaborated herein, in methanol reactor tank 106 a lower aliphatic alcohol such as methanol can be mixed with an acid catalyst such as H 2 SO4. Solution produced in methanol reactor tank 106 can be sent using two way stop cock 114 and pipe 134b to acid reactor tank 108 (for esterification of vegetable oil). Raw filtered vegetable oil can be provided to tank 108, as elaborated further.

[0077] In another aspect, at a later stage as elaborated further, in methanol reactor tank 106 a lower aliphatic alcohol such as methanol can be mixed with a base catalyst such as KOH or NAOH and solution produced can be sent using two way stop cock 114 and pipe 134a to base reactor tank 110 for transesterification/ neutralization of the esterified vegetable oil to produce biodiesel.

Static mixer 150

[0078] In an aspect, each of methanol reactor tank 106, acid reactor tank 108 and base reactor tank 110 can be configured with static mixer 150 to enable thorough mixing of contents of various reactor tanks, when required. In an exemplary embodiment, static mixer 150 can have a motor that is mounted on top of a tank the motor driving blades of dimensions 30X20 mm using a connecting shaft of length 200 mm and diameter of 11 mm.

Acid reactor tank 108

[0079] In an aspect, acid reactor tank 108 can be a borosil glass flask. In an exemplary embodiment, acid reactor tank 108 can be of a semi-spherical profile with outer diameter 228 mm, internal diameter 220 mm and height of 312 mm.

[0080] In another aspect, a static mixer 150 can be mounted on acid reactor tank 108 to mix ingredients within.

[0081] In yet another aspect, acid reactor tank 108 can be configured with a heating mantle of isomantle design (elaborated later herein) to provide heating to acid reactor tank 108 and ingredients within as required.

[0082] In an aspect, top zone of acid reactor tank 108 can be connected to heat exchanger 128 as shown, in order to carry out condensation process for recovering methanol, as elaborated further. [0083] In another aspect, acid reactor tank 108 can have a funnel 118 in its top zone as shown to pour raw filtered vegetable oil into acid reactor tank 108. Another opening can be provided to insert a thermometer in contents of acid reactor tank 108 to monitor its temperature for a fast and correct reaction.

[0084] In yet another aspect, acid reactor tank 108 can have at its bottom means to discharge its liquid contents either to beaker 140 or to base reactor tank 110. In an exemplary embodiment, such means can include a two way stop cock shown as 136 wherein one connection 138a of two way stop cock 136 can provide contents of acid reactor tank 108 to base reactor tank 110 via pipe 134c and other connection 138b of two way stop cock 136 can provide contents of acid reactor tank 108 to beaker 140.

[0085] In an aspect, in acid reactor tank 108 only reaction taking place is acidic in nature. Solution in methanol reactor tank 106 can be transferred to acid reactor tank 108 using two way stop cock 114 and pipe 134b. Due esterification process in acid reactor tank 108 glycerin and esterified vegetable oil can be produced that can further be extracted from acid reactor tank 108 as elaborated hereunder.

[0086] In an aspect, during esterification process there is a chance of evaporation of methanol from acid reactor tank 108. This gaseous methanol can be transferred to a tubular heat exchanger 128 as illustrated. Cold water can flow through outer jacket of heat exchanger 128 causing condensation of evaporated methanol in its internal pipe. This condensed methanol can be collected in beaker 142and reused during the next treatment process.

[0087] The contents of acid reactor tank 108 can then be allowed to settle in acid reactor tank 108 itself under gravity for next 6-8 hours. Glycerine being heavier can settle at bottom of the acid reactor tank 108 from where it can be collected (decanted) using stopcock 136 and connection 138b into beaker 140 whereas esterified vegetable oil ( that is presently acidic) can be transferred to base reactor tank 110 for further treatment, using stop cock 136, connection 138a and pipe 134c.

[0088] Hence, as can be understood, tank 108 can be configured to hold a reaction mixture comprising a vegetable oil, at least one lower aliphatic alcohol ( for instance methanol ) and a first catalyst ( for instance H2S04) to effect esterification of the vegetable oil and thereby produce esterified vegetable oil. Base Reactor Tank 110

[0089] In an aspect, base reactor tank 110 can be a borosil glass flask. In an exemplary embodiment, base reactor tank 110 can be of a semi-spherical profile with outer diameter 228 mm, internal diameter 220 mm and height of 312 mm.

[0090] In another aspect, a static mixer 150 can be mounted on base reactor tank 110 to mix ingredients within.

[0091] In an aspect, working principle of base reactor tank 110 is similar to that of acid reactor tank 108; significant difference being that in acid reactor tank 108 chemical reaction taking place is acidic in nature while in base reactor tank 110 chemical reaction taking place is alkaline/basic in nature to neutralize the acidic esterified vegetable oil produced in acid reactor tank 108 and so produce high quality biodiesel.

[0092] As elaborated above, esterified vegetable oil can be transferred to base reactor tank 110, with temperature being maintained constant in base reactor tank 110.

[0093] In an aspect, methanol reactor tank 106 can now have methanol with a base/ alkali (KOH or NaOH) catalyst that can be added to base reactor tank 110 by means of two way stop cock 114, connection 116a and pipe 134a.

[0094] In an aspect, during transesterificati on/neutralization process in tank 110 there is a chance of evaporation of methanol from base reactor tank 110. This gaseous methanol can be transferred to a tubular heat exchanger 130 as illustrated. Cold water can flow through outer jacket of heat exchanger 130 causing condensation of evaporated methanol in its internal pipe. This condensed methanol can be collected in beaker 144 and reused during the next treatment process.

[0095] The contents of base reactor tank 110 can then be allowed to settle in base reactor tank 110 itself under gravity for next 6-8 hours. Base reactor tank 110 can have at its bottom means to discharge liquid contents in it to beaker 146 or another similar. In an exemplary embodiment, such means can comprise stopcock 132. Initially, stopcock 132 can transfer glycerine settled in base reactor tank 110 to beaker 146 and once such transfer is complete, biodiesel in base reactor tank 110 can be transferred to another container.

[0096] Hence, as can be understood, tank 110 can be configured to hold the esterified vegetable oil, the at least one lower aliphatic alcohol ( for instance methanol) and a second catalyst ( for instance KOH ) to effect neutralization of the esterified vegetable oil,, leading to production of biodiesel. The second catalyst can be a base when the first catalyst is acidic, and an acid when the first catalyst is a base so as to neutralize the acidic/basic nature of esterified vegetable oil produced in the first step. The present exemplary embodiment is being described wherein the first catalyst is acidic and the second basic in nature.

Heating Mantle or Isomantle

[0097] In an aspect, invention disclosed can use an isomantle to apply heat to containers where required. A heating mantle / isomantle is a piece of laboratory equipment used to apply heat to containers as an alternative to other forms of heat bath. In invention disclosed, isomantle can be a high temperature heating tape (for eg, Model FGS051A of Omega Engineering) that can be wrapped around acid reactor tank 108. Stiff iron wires can further be used to hold it close to surface of acid reactor tank 108. A PID controller can be further used for precise temperature control due to the fact that the insulated heating tape gets heated up very fast.

Methanol recovery system (heat exchanger 128 and heat exchanger 130)

[0098] Biodiesel and glycerine contain surplus amount of methanol in it. After separation of glycerine from biodiesel, excess methanol can be driven off via heating and capture for reuse as elaborated above and herein.

[0099] Invention disclosed employs tubular heat exchanger i.e. Shell and Tube type Heat exchanger shown at 128 and 130 for the purpose. Such heat exchangers have the advantage that they can be designed for all pressure, temperature and flow, possibility of selecting various pipe diameters, length and economical aspect.

[00100] In an exemplary embodiment, invention disclosed can have a heat exchanger of internal diameter and external diameter as 16.5 mm and 39 mm respectively, having an inlet and outlet port for cold water at a distance of 20 mm from the two end points of length 15mm and 14 mm diameter. One end of the heat exchanger can be fitted to the mouth of the acid reactor tank or base reactor tank to collect gaseous methanol while the other end can be open through which the recovered methanol can be collected back in a beaker, as elaborated above.

Dry wash purification system

[00101] Usually, biodiesel produced is further "washed" carrying out wet washing method. However, there are many disadvantages of it like high water consumption, emulsion formation, sewage output and drying of the final product. [00102] In an aspect, invention disclosed can use dry washing instead that can avoid above problems. For the purpose ion exchange resin column and magnesol powder column as filter aid can be used.

[00103] FIG. 2 illustrates by means of a block diagram the method of functioning of a portable biodiesel production apparatus, in accordance with an exemplary embodiment of the present disclosure.

[00104] In an aspect, the method can include, at block 1, titration of raw non-edible oil. In an exemplary embodiment, chemicals required for this purpose can be N/10 KOH, neutral ethyl alcohol and phenolphthalein indicator. 250 ml of distilled water can be added to 1.4 gms KOH to prepare the titrant. About 20-22 ml ethyl alcohol can be added to 0.5-1 gms of non-edible oil sample and the solution stirred well for 2-4 minutes, Next, 3-4 drops of phenolphthalein indicator can be added into the solution. This solution can next be titrated with titrant as prepared above in order to determine the acid value of the non-edible oil. Acid value is the number of milligrams of potassium hydroxide required to neutralize the free fatty acid present in lgm of oil.

[00105] In another aspect, the method can include, at block 2, degumming of the biological material (vegetable oil). In this step 1% v/v of orthophosphoric acid can be mixed with the oil. The mixture can be stirred continuously for upto 1 hour at 98 degrees centigrade and then cooled down for 2 hours. Purified oil can be connected from upper layer of the mixture.

[00106] In another aspect, the method can include, at block 3, esterification of the purified vegetable oil to produce esterified vegetable oil. For the purpose initially 1% v/v H 2 SO4 and 20% v/v organic solvent (methanol or ethanol) can be added (for instance in methanol reactor tank 106 elaborated above) and the mixture stirred continuously for 5 minutes. At the same time the raw degummed oil can be filtered in the acid reactor tank (such as tank 108 elaborated above). Temperature upto 60 degrees centigrade can be maintained in the acid reactor tank 108 to drive off any moisture from the oil.

[00107] The solution in the methanol reactor tank 106 elaborated above can be transferred to the acid reactor 108 tank via a hose pipe having a regulator at the beginning near the methanol reactor tank. The reaction can hence start in the acid reactor tank 108 and mixture therein stirred continuously for next 2 hours at constant temperature of 60 degrees centigrade.

[00108] In an aspect, during esterification process there is a chance of evaporation of methanol from acid reactor tank. In order to recover this methanol, a tubular heat exchanger can be provided to take gaseous methanol from acid reactor tank 108 and condense it, as elaborated above. This condensed methanol can be collected in a beaker and reused during the next treatment process.

[00109] The mixture can then be allowed to settle in acid reactor tank 108 itself under gravity for next 6-8 hours. Glycerine being heavier can settle at bottom of the tank from where it can be collected and then the acid treated oil can be transferred to base reactor tank, as elaborated in step 4 hereunder.

[00110] In another aspect, the method can include, at block 4, transesterification/neutralization of the esterified vegetable oil (that is acidic in nature in this example) to produce biodiesel. Using a hose pipe, esterified vegetable oil can be transferred to a reactor tank ( for instance, base reactor tank 110 elaborated above) using gravitational flow. The esterified oil can be heated to 70 degrees centigrade to drive off any moisture and stirred vigorously. In methanol reactor tank 106, fresh methanol can be added by 20% v/v with 0.5% gms of catalyst i.e. sodium hydroxide (NaOH) pellets in bi-molar ratio in methanol reactor tank. The mixture can then be transferred to base reactor tank 110 using hose pipe and gravitational flow as elaborated above and further mixed with esterified vegetable oil there to produce high quality biodiesel. The whole mixture can be maintained at atmospheric pressure and 65 degrees centigrade, and stirred for 2-3 hours.

[00111] In an aspect, during transesterification/neutralization process there is a chance of evaporation of methanol from base reactor tank 110. In order to recover this methanol, a tubular heat exchanger can be provided to take gaseous methanol from base reactor tank and condense it, as elaborated above. This condensed methanol can be collected in a beaker and reused during the next treatment process.

[00112] The mixture can then be allowed to settle in base reactor tank 110 itself under gravity for next 6-8 hours. Glycerine being heavier can settle at bottom of the tank from where it can be collected and then the biodiesel produced can be transferred to a dry washing system as elaborated in step 5 hereunder.

[00113] In another aspect, the method can include, at block 5, an innovative washing process that can be termed dry washing. Dry washing can be carried out in two steps. The obtained biodiesel can be passed through an in exchange resin column and next magnesium silicate (magnesol) powder as filter aid to obtain pure biodiesel.

[00114] In an aspect, invention disclosed has many advantages as against present biodiesel reactors of same capacity. The advantages include increased biodiesel yield, reduced operating cost., lower manufacturing and material cost, less time consumption and energy savings ( as fluid transfer takes place using force of gravity ). Further, invention disclosed doesn't need any skilled operators, takes less time for separation of glycerin and produces enhanced purity of methanol recovered. Using drywashing, invention disclosed can produce pure biodiesel to meet international standards.

[00115] As can be readily understood, instead of methanol any other equivalent lower aliphatic alcohol can be used with a first catalyst for esterification of the vegetable oil. Depending upon the first catalyst's effect on the vegetable oil, a second catalyst can be further deployed to neutralize the esterified vegetable oil and produce high quality biodiesel. For instance, when the first catalyst is acidic (for instance H2S04, as elaborated here) in nature, the second catalyst can basic ( for instance KOH or NaOH as elaborated here), in nature. Likewise, when the first catalyst is basic in nature, the second catalyst can be acidic in nature.

[00116] In an aspect, the lower aliphatic alcohol can be selected from the group consisting of methanol, ethanol, propanol and butanol. It can be recovered using an appropriate system, for instance the heat exchange system deployed for recovery of methanol as elaborated in this exemplary embodiment.

[00117] Invention disclosed can alleviate the global energy crisis and can be particularly sustainable and useful for developing countries like India and others similar globally.

[00118] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION

[00119] The present disclosure provides for a biodiesel production apparatus that produces biodiesel to international standards.

[00120] The present disclosure provides for a biodiesel production apparatus that does not waste methanol.

[00121] The present disclosure provides for a biodiesel production apparatus that is fast and easy to operate, and has a high biodiesel yield.

[00122] The present disclosure provides for a biodiesel production apparatus that has lower manufacturing cost, material cost and operating cost.




 
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