Biodiesel:- From Soil to Soil, From People to People Suchada Butnark and Kunn Kangvansaichol On behalf of Mrs.Ratanavalee Inochanon, Vice President of Fuels and Lubricants Research Department PTT Research and Technology Institute (PTT RTI) September 3, 2007
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Biodiesel:-From Soil to Soil, From People to People
Suchada Butnark and Kunn KangvansaicholOn behalf of Mrs.Ratanavalee Inochanon,
Vice President of Fuels and Lubricants Research DepartmentPTT Research and Technology Institute (PTT RTI)
September 3, 2007
Outline
• PTT RTI and Biodiesel Research• Biodiesel Overview• Biodiesel Process and Works at PTT RTI• Biodiesel Applications• Biodiesel Current Issues• Biodiesel R&D Trends • Conclusion• Acknowledgements
PTT-RTI and Biodiesel Research
TRAINING CENTER
FUEL & LUBE LAB.
ANALYTICAL LAB.
GYMNASIUMGYMNASIUMACCOMMODATIONACCOMMODATION
ENGINE TEST LAB.
UTILITY
PTT TRAINING CENTER
Total Area: 75 Rai
PTT-RTI and Training Center
Research Capability
Researcher 51Technician 15Staff 22
• NGV development with OEMs (commercialized in 2007)• International Standard Natural Gas and Pipeline Operation and Maintenance Excellence
Natural Gas
• Capability to research and develop process, catalyst, product development (engineering plastics, nanomaterials)
• Network and Partnership within PTT Group for combined strength• Technical and R&D Service Center for Petrochemical and Refining Business Group
Petrochemical and Refining
• World class fuel and lubricant product development and lab facility• Collaborative development with OEMs for superior quality products• Leader in cleaner products
Oil
PTT-Research and Technology Institute
• The Nation’s Qualified Biodiesel Analysis and Engine Testing Labs
• Fuel Formulation and Product Development
Biodiesel Projects at PTT RTIProjectsNational Interests
• Superior PTT Biodiesel B5 Formula with Suitable Lubricant
• PTT Biodiesel Pilot Plant (Complete by July 2007)
• Joint Study on Biodiesel from Variety of Feedstock (CPO, CJO, UCO) (TISTR)
• Biodiesel as Diesel Lubricity Additive (Patent Pending)
• How is Biodiesel Performance and Compatibility?
• Is Biodiesel Quality Consistent?
• How to Produce High Quality Biodiesel from CPO, CJO and UCO with Optimized Cost?
• What about Lubricant?
• PTT-CP Joint Study on Fully Integrated Palm Biodiesel Industry (on going)
• Collaborative Research and Development Project on Jatropha Biodiesel for Diesel Vehicles (PTT-KU-Toyota 2006-2008)
• PTT-MTEC Joint Study on LCA and LCCA Analyses on Biodiesel Industry(on going)
• Low Yield, Not Competitive with Other Plants
• How to Make BiodieselIndustry Sustainable without Government Subsidy?
• Environmental and Economic Issues on BDF
Biodiesel Overview
Overview
• What is Biodiesel?– Biodiesel is an alternative fuel that can be made from animal
fats or vegetable oils also known as Fatty Acid Methyl Ester (FAME)
– Main natural sources are rapeseed, soy bean, palm oil, used frying oil, animal fats and tallow
• Biodiesel for automotive fuel is specified by an European Norm EN 14214 or ASTM D6751
• Biodiesel Production at PTT-RTI– From lab-scale to pilot plant
• Feedstock Selection • Lab-Scale Experimental
– How to make biodiesel that passes specification? – New approach on post-treatment– Results & Discussion– Specifications
• Pilot-Scale Experimental– Results & Discussion
Conventional Biodiesel Production at PTT-RTI - 2007
• Goals– To optimize production from various types of crude vegetable oils– Developing in-house standard operating procedure (SOP) that results
in B100 under DOEB’s specification through lab-scale unit – Properties-composition relationship – Process scale-up– Pilot-scale demonstration plant
• Deliverables– Operating units for conventional biodiesel production (Lab & Pilot)– Producing B100 under DOEB’s specification from lab and pilot scales– Consistency in lab-scale production of B100– New successful approach on post-treatment
Fat Triglycerides in native fat or oil- Left part: glycerol- Right part from top to bottom: palmitic acid (C16:0), oleic acid (C18:1), linolenic acid (C18:3)- Chemical formula: C55H98O6- Molecular weight: 854- Right part can be varied from C12:0, C14:0, C16:0, C18:0, C18:1, C18:2, C18:3, etc.- Molecular weight ~ 700-900
0.050 max0.50 max0.80 max0.20 max0.20 max0.02 max0.25 max860-9000.30 max0.02 max
0.0010 max1 max6 min0.0024
96.5 min12.0 max120 max0.20 max
} 5.0 max
} 5.0 max0.0010 max
4.347162
0.0100.20
<0.2500.110<0.050<0.0050.074*880.50.20
< 0.0050.0003
1a22.0 (0.4)
0.000499.4Nil86
0.05Nil
1.74NilNilNil
Heat of Combustion (J/g)
Diesel Type Heat of Combustion (J/g)
Conventional Diesel 45,968
B100(PME) 39,550
B100(SBME) 39,350
B100(JME) 39,000
B100(SFME) 39,450
Source: TISTR
Pilot-Scale Demonstration Plant
Biodiesel: Pilot Plant and Operation Supports
Second floor
Ground floor
Storage tanksPilot Plant – Plot Plan
• Biodiesel Pilot Plant for future Fully Integrated Biodiesel Complex (as in Master plan on Biofuels 2006PTT)
• NEW FORMULATION DEVELOPMENT through in-house production with VARIETY OF FEEDSTOCK including used cooking oil, palm oil, jatropha oil, etc.• COST REDUCTION through process optimization and new technology implementation• SHOWCASE with ultra-low waste process with high quality EN14214 standard fuels • Completion in July 2007 (with guaranteed quality of BDF from CPO, UCO and CJO)
• Pre-treatment– Filtration, Degumming with water and H3PO4– Esterification by acid catalyst (in case of FFA > 5%)
• Transesterification– Methanol:Oil = 9:1– KOH:Methanol = varied by FFA contents (correlation curve)– Temperature = 60ºC– Second step transesterification = constant KOH/Methanol solution
• Post-reaction– Semi-Dry washing (Oil:Water = 22:1)– Vacuum dehydration at 90ºC– Filtration (75- and 1-micron filters)
Schematic Diagram of Pilot-Scale Biodiesel Production at PTT-RTI
Production Cost of Biodiesel
Oil82%
Chemicals12%
Utility6%
Source: PTT Research and Technology Institute Team Analysis, data from 5 commercial licensors
Components Cost (THB) Cost (%)
Oil 16.00
2.69
Utility (Water, Steam, Electricity, etc.)
1.13 6%
82%
Chemicals (Methanol, KOH, H2SO4)
12%
• The price of biodiesel mainly depends on the price of oil feedstock just like HSD on crude oil.• The other costs come from chemicals, utility and labour (excluded in the analysis) just like in the refinery
Results and Discussions (Pilot-Scale B100 Production)
• Successfully produced B100 that pass specification
• Esterfication of high-FFA feedstock– FFA has been reduced from 15% to 0.3%
• Conversion yield > 90% for most cases
• Only 5% of washing water has been utilized and removed effectively to be below 500 ppm as DOEB’s specification
• Free fatty acid value seemed to be high for JME production due to vacuum dehydration at 90ºC
Analysis Results of UCME, PME, JME
Item Property Unit Specification UCME PME JME
12345678910111213141516171819202122232425
Viscosity at 40ºC Flash pointWater contentTotal acid numberMonoglycerideDiglycerideTriglycerideFree glycerinTotal glycerinDensity at 15.0ºC10%Carbon residueSulfated ashSulfur contentCopper strip corrosionOxidation stability at 110ºCTotal contaminationMethyl esterLinolenic acid methyl esterIodine valueMethanol contentSodiumPotassiumCalciumMagnesiumPhosphorus
cSt.ºC
%wt.mg KOH/g
%wt.%wt.%wt.%wt.%wt.
kg/m3
%wt.%wt.%wt.
Numberhr.
%wt.%wt.%wt.
g Iodine/100 g%wt.
mg/kgmg/kgmg/kgmg/kg%wt.
3.5-5.0120 min
0.050 max0.50 max0.80 max0.20 max0.20 max0.02 max0.25 max860-9000.30 max0.02 max
• Lab-scale: successfully produced various B100 types that pass specification– Developed in-house SOP that makes qualified B100s– Consistency in B100 production
• Pilot-scale:– Optimization of conditions for B100 production– Handling high free fatty acid up to 20% through esterification technique– Semi-dry washing technique using only 5% water
• Potential technologies of biodiesel production and analyses at RTI– Constructing a 50-L scale unit that can be modified/retrofitted for:
• Heterogenous catalysts• Co-solvent method• Ultrasonic method• Low wastewater production• Lipase-catalyzed production for community biodiesel
– HPLC utilization for compositional analysis
Biodiesel Applications
– Fueling with B5/Biodiesl supports domestic industry and agriculture and save money from imported oil and support sufficiency economy– Fueling with Biodiesel supports R&D
Should we use Biodiesel?
- Fueling with B5 helps lower the emission- Fueling with B5/Biodiesel minimizes the environmental impact
National Economy Benefit
Consumer Benefit
Environment Benefit
– Fueling with B5 can help you save more money than with Petro Diesel
Yes, we should because …
Fueling with B5 helps lower the emission
• Emission Impact Summary– Depend on Percentage Mixture (B2-B100)
• THC reduction: 10 - 60%• CO reduction: 10 - 40%• Black Smoke reduction: 10 – 60%
– Since biodiesel contains oxygen content, it improves the combustion of the engine
• NOx tends to increase (5 – 40%) but needs to investigate further
Environment Benefit
EmissionFuelsTHC NOx CO PM Formal. Acetal.
PSME B2 NS NS NS NS NS NS -14%
PSME B5 -12 % NS NS -9% -14% NS -15%
PSME B20 -26% +7% -18% -10% -10% -27% -22%
PSME B100 -56% +23% -38% -59% -22% -53% -66%
RME B2 NS NS NS NS NS NS -16%
RME B5 NS NS NS -11% NS NS -23%
RME B20 -17% +11% NS -34% NS -28% -98%
RME B100 -29% +34% -18% -67% +43% NS -60%
BlackSmoke
Source: PTT Research and Technology Institute
Fueling with Biodiesel minimizes the environmental impact
• Life Cycle Analysis of Biodiesel compared to Diesel
Fueling with B5/Biodiesl supports domestic industry and agriculture and save money from imported oil and support sufficiency economy
• Agriculture has more channels than only food but also energy. This results in price stability.• Biorefinery Industry in Thailand to add value to every part of palm e.g. animal feed, paper
pulp, fertilizer• Labor throughout various industries
Palm Farmers Oil Extraction Industry
Biodiesel Industry
Picture
For Biodiesel B100 1 Liter, we need
5.88kg of fresh fruit bunch 1 Liter of crude palm oil 1 Liter of biodiesel B100
Price 2.70THB/kg 17THB/Liter 22-24THB/Liter
Money circulating in that industry (assumed 8.5MML/d in 2012 as B10)
135 Million THB/d or 50,000 Million THB/y
140 MillionTHB/d or 53,000 Million
THB/y
187-204 Million THB/d or 68,000-74,000 Million THB/y
Reduced Imported Oil 202 Million THB/d or upto 75,000 Million THB/y
Assumption 17% oil yield 100% conversion yield
By-products not included By-products and electricity not included
By-products not included
Source: PTT Biofuel Masterplan 2006 Team Analysis
National Economy Benefit
Fueling with Biodiesel supports R&D
• R&D throughout the whole value chain– Seed and Plantation Management
- Solid catalyst/Co-solvent/Supercritical Methanol/Enzyme lipase- Ultrasonic/Microwave Enhancement- Production from variety of feedstock
• Washing Process- Dry Washing with Adsorbent/Molecular Seive
• New Process- Hydrotreating and integration to existing refinery
Product Development Product Development (control and improve the quality of (control and improve the quality of biodieselbiodiesel from various feedstock)from various feedstock)
• Mixture higher than B5• Improve oxidation stability of various feedstock• Improve cold flow property of biodiesel from various feedstock
Source: PTT RTI Team Analysis
Conclusion
• From today presentation, we know …1. What Biodiesel is…,2. The activity of Biodiesel R&D at PTT RTI, from Lab to Pilot-
plant3. We should use Biodiesel because of benefits to environment,
national economy and consumers,4. There are many issues related to biodiesel quality and
solutions, and5. Where the Biodiesel R&D is heading.
Acknowledgements
• REVO International, Japan
• TISTR
• Summer Interns from Srinakharinwirot and SilpakornUniversities