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Raw, unwashed
biodisel after just 15 minutes in the processor
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The raw material: Long
molecular chains of fatty acids with a glycerol
(also known as glycerine) molecule attached on one
end are known as glycerides. Three of these
naturally bond together, forming tri-glycerides.
Vegetable oil and animal fat is made of these
tri-glycerides.
The
chemicals: Caustic soda or potash is
mixed with methanol to form sodium or potassium
methoxide which will break these bonds.
The
reaction using fresh vegetable oil:
Add the methoxide.
It first attacks the tri-glyceride bond, releasing
one glyceride, leaving a di-glyceride still bonded,
then it attacks that bond and you have 3 separate
glycerides.
The methoxide then
breaks the glycerol molecule free from each
glyceride in turn and replaces it with a methanol
molecule. When complete, you will have three methyl
esters (commonly known as biodiesel) and three
glycerol molecules. Since these methyl esters come
from vegetable oil which is made from fatty acids,
the biodiesel we make is known as Fatty Acid Methyl
Esters, or FAME for short.
The
reaction using waste vegetable oil and animal fat:
Identical apart from
the fact that used or waste vegetable oil also has
fatty acid chains which have already broken away
from their glycerol molecule under the heat used
when cooking. These are known as free fatty acids
(FFAs) and they cannot easily be reattached, so we
neutralise them with extra caustic.
Agitation: To
ensure that the methoxide can reach the all of the
glycerides, we need to mix them together
continuously until the reaction is complete.
Temperature: The
reaction proceeds better above 40C and reaches a
maximum rate around 60C, above which the methanol
boils and evaporates (64.5C).
How Long
Does It Take?
The speed of the
reaction depends on a large number of factors, such
as: batch size; temperature; agitation; water
content; the amount of chemicals; purity of
chemicals, etc., but should normally be completed
in less than 30 minutes from when the methoxide is
first added.
How do we
know when the reaction is complete?
HM Revenue and
Customs state that to qualify as biodiesel for
exemption from fuel duty and to form part of your
2,500 litres allowable, the finished fuel must
comprise at least 96.5%
methyl esters.
We work with 4
alcohols: propanol, ethanol, methanol and glycerol
which each have different dissolving powers, so we
can use a simple test.
Dissolving
properties:
|
Alcohol type
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Vegetable oil
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Free Fatty Acids
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Biodiesel
|
|
Propanol
|
Yes
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Yes
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Yes
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Ethanol
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Yes above 50°C
|
Yes above 50°C
|
Yes
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Methanol
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No
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No
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Yes
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Glycerol
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No
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No
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No
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Take a sample (many
people suggest 3mls) of what you have just made and
try to dissolve it in methanol (usually 27mls,
hence it is called the 27/3 test). If it all
dissolves, it must all be methyl esters (biodiesel)
and the reaction is complete. If any won't dissolve
but simply drops to the bottom of the
beaker/cup/bottle then that must be vegetable oil
that has not yet been turned into methyl esters. No
amount of shaking will make it dissolve, nor will
adding more methanol. Instant result: no drop-out =
complete reaction; any drop-out = incomplete
reaction.
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Drop
out clearly visible as a yellow band
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100/10 test:
We prefer larger samples to give an easier
to calculate and more accurate percentage of
conversion and always use 10mls of biodiesel to 100
mls of methanol. After vigorous shaking and time to
settle we suck the drop-out into a 10ml or larger
syringe, stand it up vertically and let it settle.
Each 1ml of oil that drops to the bottom of the
syringe represents 10% oil not yet reacted, while
later we switch to a 1ml graduated syringe for
finer accuracy, where each 0.1ml in the syringe
represents 1% not reacted.
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Test
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Photo
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% Complete
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Action
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First test after 5 minutes mixing;
obviously not complete, with almost half still not yet reacted but
this result is promising as it shows that the reaction is proceeding
and more than half has already reacted
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Approx 4.5ml drop out indicates maybe
55% completion and 45% wvo still to convert
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Turn pump/agitator back on
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Second test after 10 minutes; drop out
is much smaller so we switch to a 1ml syringe graduated in figures to
0.1ml and then lines down to 0.01ml . This is a good test result and
it is likely to finish with another 5 or 10 minutes mixing
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Here a 0.58ml drop out shows 5.8%
remaining or a 94.2% completion; still not finished and definitely
not yet legal
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Turn pump/agitator back on
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Third test after 15 minutes; drop out
is now difficult to read accurately, we estimate around 0.18mls
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0.18ml drop out shows 98.2% completion
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Legal and finished, with the methyl
esters content at 98.2%. Settle and drain glycerol then pump the
biodiesel into the wash process
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Fourth test after 20 minutes; not
actually necessary but if we continue the reaction, we end up with a
drop-out so small as to be almost impossible to read, we guess here
around 0.07ml
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0.07ml shows a 99.3% conversion and
the remaining wvo is now too small to worry about
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Reaction finished leaving high quality
biodiesel well above minimum legal specification.
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Now we just drain
off the glycerol, wash it and we have pure
biodiesel. See how quick and easy it is?
Easy, isn't
it? So why do we have problems?
Warning: If you
regularly make good quality biodiesel in less than
30 minutes then you need read no further. We do not
want to change anybody using a successful method, a
tried and tested processor and/or a consistent
recipe. But if you don't, then read on.
The problem is us.
We have different processors with different
components, we use different recipes, we use
different temperatures; we use different base rates
for chemicals, and if one reaction is not perfect,
or we see a new article or recipe on our favourite
forum, we simply change something for the next one.
We've all done it.
Imagine what the
result would be if a baker changed the bread recipe
each and every single time he/she baked bread, or
if a brain surgeon used a totally new, untried
method for each new operation.
No wonder we have
problems. We never find the perfect processor,
method and recipe and then stick to it religiously,
batch after batch. So, what's the answer? What
should we do? What is the right reaction
temperature? What is the correct base rate? Where
do we start?
The simple fact is
we make so many changes at once that we never
actually know what has worked and what didn't.
Also, we sometimes have to change something else to
compensate for the change that we originally made.
Benchmark
biodiesel processor:
The
only way to find out is to go back to basics and
design and build a “bench mark”
processor. The actual design is irrelevant, as it
is just the starting point around which changes can
be made, but it needs to be capable of making
biodiesel, and it needs to allow total monitoring
of what is happening during the reaction. It should
be constructed from readily available components,
which must be easy to change between reactions.
We
chose a plastic HDPE cone of 220 litre capacity as
it had a nice big screw top hatch so we could open
it up and see exactly what was happening during the
reaction. Similarly, we chose 1” ID clear
plastic wire reinforced tubing to connect the
system, as, again, this allowed full viewing of the
mixture as it reacted. The pump we connected was
the Tam 105 rated at 40 lpm (our's is, but some
seem to quote 33 or 38 lpm), a trusty little pump,
widely recommended. For getting fluids in and out,
we fitted an inlet/outlet tube, connected through a
1” ball valve to a 'T' piece on the inlet
(suction ) side of the pump. With the pump running,
we could use this to suck in WVO, water, methoxide,
and with the pump off, it could be used, being the
lowest point of the system, as a drain valve for
water, glycerol, and biodiesel. For heating we
installed a 3Kw stainless steel 27” immersion
heater controlled by a PID with a range of 0°C
to 200°C
and accurate to 0.1°C
with a built in 16A mains relay to directly control
the heater.
Once
we had the design, we then needed to eliminate the
natural variations that occur, namely different
batches of WVO and different chemicals. The easiest
way was to bulk buy. We bought an IBC full of 1,000
litres waste vegetable oil from a single source and
thoroughly mixed up the contents, before allowing
it to settle for 7 days to eliminate water. We
titrated the oil several times and took the average
reading of 4.5. We ordered a fresh IBC of methanol
at 99.9% purity, a fresh 25Kg sack of Potassium
hydroxide flakes at 90% purity and a fresh 25 Kg
sack of sodium hydroxide pearls at 99.9% purity.
Finally, we needed to go back to basics with the
recipe to use. From “Journey to Forever”
we chose their simplest “all in one”
process, being a 100 litre batch carried out at
50°C,
and elected to use their lowest chemical base
rates, being 20% methanol and 3.5g per litre for
sodium hydroxide and 5.45g per litre for potassium
hydroxide (3.5 x 1.4 / 90%).
Once
all these are set, we then carried out a “bench
mark” reaction and noted the time it took to
reach completion, defined as reaching 96.5% methyl
esters content in line with HMRC specifications,
confirmed by the 10/100 methanol test (a modified
27/3 test), which gave very accurate methyl ester
percentages. This time taken was 2 hours and 15
minutes.
Once
we had our bench mark, all that was required was to
select one and only one variable to change for the
next reaction from a relatively short list of
possibles.
Variables
to be tested were:
The
reaction vessel; copper, steel, plastic, cone,
cylinder, etc
The
pump; 40 lpm, 80 lpm, 110 lpm centrifugal and self
priming
Temperature
controller; immersion thermostat, PID
Base
rate caustic; 3.5g, 4g 5g 6g, 8g, 10g per litre
(and equivalent for KOH)
Basic
methanol; 15%, 17%, 20%, 25%
Reaction
temperature; 30°C,
40°C,
50°C,
60°C,
65°C
Methoxide
introduction; venturi, all in, 80/20
WVO
water content; water removal, water addition
While
there are only 8 variables, each one can have many
different values, meaning that they can probably be
combined to give many thousands of combinations
altogether.
We
carried out one reaction after another, changing
just one, and only one, variable each time, and
measured the time taken to completion, or 3 hours
which was classed as a failure. After each
reaction, we reset the variable and chose another
variable or setting. We quickly found that some
variables made almost no impact at all on the
reaction time, while others showed fantastic leaps,
faster or slower. Variables that showed a reaction
time difference less than 15 minutes faster or
slower were disregarded. Variables that made large
differences were explored in more detail.
Over
the next few weeks we will be releasing all of the
findings, but we start with the single biggest
variable, and definitely the most surprising in
that it is barely mentioned on any of the web sites
or forums that we have ever found. It made a
difference in reaction time that was simply
staggering.
Agitation
energy:
By far the biggest drop in reaction
time was when we changed the pump. The original
Tam 105 rated at 40 lpm gave a reaction time of 2
hours 15 minutes, yet changing to a 80 lpm
centrifugal pump reduced that to just under 30
minutes. And changing to a 110 lpm centrifugal
pump dropped even that quick time to just over 12
minutes for a 100 litre batch. We were astounded
and set about testing the impact of pump size and
design, and when we ran out of pumps (the largest
we had was the 110 lpm), we just dropped the batch
size (processing just 25 litres meant that each
litre received over 4 times the agitation compared
to processing 100 litres with the same pump).
Our table of results shows average
time taken to reach 96.5% completion (we decided
that testing the 40 lpm pump was a total waste of
time):
|
Pump size
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25 litre batch
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100 litre batch
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150 litre batch
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180 litre batch
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110 lpm
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7 minutes
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12 minutes
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30 minutes
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1 hour 25 minutes
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80 lpm
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15 minutes
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30 minutes
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1 hour 30 minutes
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Over 9 hours
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*
failure simply meant that we had not reached 96.5%.
In fact, after 9 hours, it was at 94% and we
calculated it would take almost another 4 hours to
complete, as the conversion progresses in a series
of “half lives”. If the half life of a
particular reaction is 1 hour, it means that after
1 hour, 50 litres of biodiesel have been produced,
after 2 hours we have 75 litres (50 litres plus
half of the remaining 50 litres), after 3 hours we
have 87.5 litres (75 plus half of the 25
remaining) after 4 hours we have 93.75, after 5
hours we finally have 96.88, but the last 10 litres
have taken over 2 hours to produce compared to 50
litres in the first hour.
The
results show a 3 startling facts
You can make biodiesel at 96.5% in
under 7 minutes
If it takes 7 minutes to make 25
litres it should also take 7 minutes to make 100
litres, 500 litres or any quantity you choose
Our 110 litre pump, which we
considered over sized, struggled to process 180
litre, taking 12 times longer than it should,
while the 80 lpm pump failed altogether
These facts prompt the question; how
on earth does anybody make good biodiesel in a
sensible time if they use the Tam 105, or indeed
any pump, rated at just 40 lpm, and why are some
processors sold on ebay with a laughable central
heating pump attached?
For
Your Information: most of the above reactions have
been videoed, but the actual times recorded are
irrelevant and not the important issue. What we can
guarantee in every single case, whatever equipment
you use, whatever WVO you use, whatever chemical
base rate you use, is that reacting a batch volume
of just 25 litres in your normal processor will
always take considerably less time to complete than
reacting a batch of 100 litres or 150 litres. Case
proved.
Try
it for yourself, please. Get your own figures. It
is really very easy and completely free; no need to
buy a larger pump to test against yours; no need to
make any changes to your processor. Just decrease
your batch size.
First, make a 100 litre batch (or
whatever size your processor normally makes) in the
normal way and time exactly how long it takes to
finish. Let's say it takes 1 hour 30 minutes.
Assuming you cannot heat a batch of 20
or 30 litres because of the placement of the heater
element, put another full batch into your processor
in the normal way. Heat the oil to your normal
temperature. Titrate in the normal way. But just
before you mix up the methoxide, turn off the
heater (and leave it off for the duration) and
drain off enough hot oil so that the remaining oil
left inside the processor is less than the flow
rate of the pump you are using. e.g. if you use a
40 lpm pump, drain off 75 litres of the oil from
your reactor into clean drums for processing later,
leaving just 25 litres inside. Now mix up enough
methoxide for just 25 litres, get it all into the
processor as quickly as possible in a single go
(even pouring it directly in if that is possible)
and then react in a single continuous process and
time exactly how long this reaction takes, but be
ready for a fast, sometimes startlingly fast
reaction.
By the way, if anyone wants to see the
most boring 20 minute video of a complete reaction
of 100 litres using our 110 lpm pump, start to
finish, then we will upload it onto Youtube and
give you the link. The fact that we can get the
reaction completed, including settling and testing
within 20 minutes should say it all. But why watch
us doing it? Just try it for yourself, it costs
nothing and you get biodiesel at the end of the
test.
So
why is agitation so important?
The following is pure logic, not
chemistry or rocket science.
Heat a batch of WVO in a large steel
drum, gently pour in the correct amount of
methoxide and then stir it just once gently with a
large wooden spoon and sit back and wait. What will
happen? We all know what will happen. Nothing.
After all, that's why we run the
pump/agitator/stirrer during the reaction, isn't
it?
Now take another batch, do everything
the same, but this time pump/stir it properly
throughout the process and we all know what will
happen. We will make Biodiesel.
It couldn't be clearer. If we don't
agitate enough, the reaction never finishes. If
everything else remains identical but we increase
the agitation, we make biodiesel.
Put
another way, if the energy of the agitation is
insufficient, the reaction cannot ever complete.
And for those who believe that just leaving it a
bit longer will eventually make it work, try
heating your house with a single candle by leaving
it burning a bit longer. Not enough energy no
matter how long you leave it.
Agitation
consists of two components; vigour and duration.
Stirring gently with a wooden spoon could be
considered the least vigorous, while using an
industrial strength food whisk at maximum setting
could be considered towards the most vigorous. As
vigour increases, the duration can be reduced.
Pumps vary in design and vigour. A
self priming pump works on the paddle wheel
principal. As a vane passes the inlet, it creates a
suction and draws in a quantity of oil behind it.
As it turns, the oil is moved forward until it
reaches the outlet, where it is driven forward and
out by the vane behind it. It is considered to be
at the very gentle end of the vigour spectrum. A
centrifugal pump has an impeller, often containing
multiple sharp metal blades or a helical twin plate
arrangement. As these spin, oil is drawn into the
centre and flung outwards under centrifugal force
at high velocity towards the outlet. These are at
the very vigorous end of the agitation spectrum.
Flow rate gives an indication of the
power of the pump, although it is not, in itself,
an important factor. A large flow rate self priming
pump, say 60 lpm, will pass more litres through it
in any given minute than a small centrifugal pump
of say 40 lpm, but will provide far less agitation
of the oil/methoxide mixture.
Conclusion:
Agitation is more important than flow rate, so
centrifugal wins hands down over self priming, and
the larger the centrifugal pump, the greater the
agitation and the shorter the reaction time. If you
want to process batches of 50 litres, a 40 lpm pump
might cope. For a batch size of 100 litres you
should not consider anything much under 100 lpm.
Above 100 litre batches, you should be on a minimum
of 100 lpm, preferably 150 or 200 lpm would be even
better. * we see that our favourite supplier,
Biotecengineering (www.biotecengineering.co.uk),
has just launched a new 165 lpm centrifugal pump
and we'll be getting one very soon. Thanks Chris!
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110lpm
pump
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Reasons why your agitation
energy might be too low:
If your test showed a problem with
batch size, there could be many reasons, other than
pump size. Here we list all we can think of;
Flow rate too low: If
you use a pump to agitate, then be aware that the
stated flow rate is measured using water. Oil is a
lot more viscous, even when hot, so a 40 lpm pump
might achieve less than 20 lpm when pumping oil,
and even this will reduce as glycerol forms, as
this is not only even more viscous but far denser,
too. Get a more powerful pump. 125 litres of oil
and methanol might take somewhere between 4 and 8
minutes to go through a complete cycle if connected
to a 40 lpm pump, meaning 90% of the oil and
methoxide is sitting around doing absolutely
nothing all of the time. It should take under a
minute to cycle the entire batch size, so if you
can't afford a new pump, reduce your batch size.
Wrong type of agitation: Not
all pumps operate in the same way. Open up a TAM
105 and you find a multi-bladed brass impeller that
is absolutely ideal for thrashing and churning the
oil and methoxide into reaction. Other effective
pumps have two brass plates fitted together with a
gap of a couple of millimetres containing multiple
tapering helical chambers. Oil is compressed into
the central narrow end of the helical chambers and
is flung vigorously outwards under amazing
centrifugal force, providing very high mixing and
agitation energy.
Open a self priming pump and the
operation is totally different. Oil is moved in
chunks by a gentle sweeping blade tipped with a
rubber or synthetic seal, operating in a smooth
chamber. While a particular pump may achieve 60 lpm
and sound good, it will do little to mix the oil
and methoxide (think of stirring with a wooden
spoon as opposed to whisking with a food mixer).
Narrow
pipework:
Your pump will almost certainly have at least 1”
BSP female threaded inlet and outlet, meaning 1”
ID or internal diameter, and using Πr2
we
find the inlet and outlet cross sections are 0.79
sq inches each. Many
people install a 1” BSP to 22mm reducer and
then use 22mm copper pipes ( I did on my first
processor).
But
copper pipe is measured OD or outside diameter, so
a 22mm pipe having 1.5mm walls will have an ID of
22 – 3 = 19mm and using Πr2
you
get a cross section of 0.44 sq inches. No prizes
for guessing what almost halving the cross section
of pipework from 0.79 to 0.44 does to the flow
rate? If your pump has a 1” inlet and outlet,
then it will produce its maximum flow rate using 1”
ID pipes, so use 1” ID pipework and get
maximum flow rate. If using copper, switch to 28mm
(OD so 25mm or 1” ID).
Restrictions: Many
copper cylinders have baffle plates welded inside
just in front of the bottom inlets to stop the
incoming water from stirring up the contents that
have settled to the bottom of the cylinder. These
will seriously restrict the flow rate into the
cylinder, even if the pipework is of good size.
Remove them if possible or find a cylinder with no
baffles. 90°
bends in copper pipework seriously disrupt the flow
rate and create a back pressure, and if you have 2
or 3 in series, you will not be getting anywhere
near the pump rating. Reduce the number of 90°
bends as much as possible, consider bending 28mm
pipes in a gentle continuous curve instead..
Venturi: While the
principal of a venturi seems sound, it is usually
the exact opposite of what you need and the worst
thing you can do. Why?
Dribble the methoxide into the oil too
slowly and the pump thrashes mostly pure oil, as
there is no methoxide nearby with which to react.
Result; unreacted oil ends up back on top of the
processor contents, wasted energy and wasted time.
Add it too fast, and you thrash spare methoxide but
it has no unreacted oil nearby to react with.
Result; unreacted methoxide ends up on top of the
processor contents, wasted energy and wasted time.
If you get the flow rate exactly right, inserting
all of the methoxide in the same time that your
pump takes to cycle the entire contents of the
batch in your processor, it can help, but it might
take 10 minutes to get all the methoxide in, and
our complete reaction only takes 12 minutes! Get a
better pump.
With
a decent sized pump, one having good agitation and
a flow rate larger than the batch size, the entire
contents of the processor are thrashed and churned
as much as 2, 3 or 4 times every single minute as
they pass through the pump. Oil in our processors
never sits still and never gets thrashed without
there being plenty of methoxide immediately around
it. After the batch has finished the first complete
cycle through the pump, usually in less than 60
seconds, the methoxide is already fairly evenly
distributed and each subsequent cycle through the
pump thrashes it into a reaction with the WVO.
80/20 methoxide:
Many people add the methoxide in two
batches, 80% at first then, after half an hour or
so, you let it settle, drain off the glycerol and
add the remaining 20%. The principle is simple.
With less volume being processed, the agitation
energy is higher. And draining off the glycerol
relieves even more strain on the pump. But why are
you using a pump that cannot cope with a full
batch? And why is it taking half an hour anyway?
This process always leads to ever
higher base rates. Glycerol is brilliant at
absorbing or dissolving water, methanol, caustic
and soap. When the glycerol is drained off after
30 or 60 minutes, it always takes with it unreacted
methoxide, caustic and methanol. Adding the next
20% does not replace this. Remember you did the
titration and everything that you put in is
actually needed. So how can this reaction now
complete with 5% or 20% of the methoxide and
caustic having being drained off and outside the
processor before it has done its job? It cannot
unless you overdose with caustic and methanol to
compensate. Many people who use 80/20 often also
use base rates of 5g, 6g, even 8g NaOH whereas we
use 3.5g for good oil (titration value between 1
and 4) increasing to a maximum of 4g for WVO with
high titration values (above 5).
Apologies:
Again, if you make consistently good
biodiesel, with high percentage completions and
high yields in well under an hour, then you might
just want to carry on doing what you are doing and
ignore this. We won't be offended. You see, we're
not trying to sell you anything, just help you.
Everything we state, we tell you how to test it for
yourself.
Then again, even if you are making
good biodiesel in less than an hour, how long does
it take to make a 25 litre batch and find out if
you could be doing it even quicker? and what harm
can it really do? The very worst it can do is prove
that your agitation is not good enough, but then
you would already know this as it is almost
impossible to make 100 litres of 96.5% biodiesel in
less than 30 minutes without sufficient agitation
energy.
Maybe you're happy doing what you're
doing. Fine. But speaking personally, if I need 300
litres of biodiesel, I'd rather make 2 consecutive
batches (taking 2 hours in total including heating)
of 150 litres each one morning, let it settle for
at least one day (three being the optimum), then
dry wash it in a single batch (300 litres at 3 lpm
takes 100 minutes or less than 2 hours), than
struggle making 3 separate batches that each take 2
or 3 hours to complete, taking maybe a whole
weekend. Where's the fun in that?
When
it all goes wrong:
Sometimes we get it wrong. Sometimes
the reaction doesn't complete in 30 minutes, and we
know it probably never will. So what do we do?
Simple. As soon as you suspect the
reaction has failed, turn the pump off, let the
glycerol settle, then drain it off as if it had
finished. Don't try to titrate what you have made
for another reaction as it is full of caustic and
soap and don't, please, do another base reaction
using 3.5g per litre and 10% methanol as some
people tell you. Try this instead.
Do the 10/100 methanol test, shake it
up, let it settle out, suck the drop-out into a
syringe and work out how much has reacted and how
much hasn't.
Then we take the remaining batch size
(what's left after draining off the glycerol) and
multiply it by the % unreacted, e.g. if we are left
with 100 litres in the processor and the drop-out
is 4.2mls, then 58% has turned into methyl esters
(and dissolved) and 42% remains as oil. Or to put
it in litres, 58 litres of the oil have gone and
are now methyl esters and 42 litres is still oil.
We also assume that any FFAs have reacted, as they
tend to go first, so now we treat what's left as
fresh oil.
Even though the batch size is still
100 litres, there are only 42 litres of fresh oil
in there. 42 litres needs 8 litres of methanol at
20% and 147g NaOH (3.5g base rate x 42 litres). Mix
a fresh batch of methoxide and chuck it in for a
second reaction. This one will finish.
I know it's fun making your own
processors, inventing bits, overcoming challenges,
but ask yourself this question and give yourself an
honest answer.
If
you wake up one morning and decide you want to
become a successful Formula Renault motor racing
driver, would you:-
a) visit a motor racing dealer who is
a specialist in Formula Renault, ask for and take
his advice and then buy the best complete car (new
or used) that you can afford, or
b) head down the scrap yard and local
motor accessory shop, buy loads of bits, download
plans from the internet and then spend weeks and
weeks building your own?
And if you chose b) what are your
chances of winning anything at all? Ever?
So why, if we want to become a
successful biodiesel producer, do we always choose
option b)? I know I did and the only reason I did
it, all those years ago, was to try to save money.
But if I now look in my garage and
count up the cost of copper cylinders, pipes and
fittings, the drills and thread cutting taps, the
bench drills, angle grinders, blow torches, and so
on, and so on, and so on, I know that I have spent
far more, in total, than if I had bought a basic
complete processor. I also know the number of
batches I have disposed of, the number where the
yield was pitiful, the vast quantities of “chicken
soup” emulsions, the huge amount I've spent
on wasted chemicals, the huge electricity bills and
so on, and so on. Then add in the sheer
frustration, the anger as yet another batch fails,
the money spent on fossil diesel because mine
wasn't ready when I needed it.
I have not saved any money. In the
end, I bought professional equipment anyway. And
what a dream it is to use.
I can fill the processor with 150
litres of oil in minutes, heat it in well under an
hour, titrate, add the methoxide, set it going,
then go and have a cup of tea and a biscuit, go
back and turn it off. It has always has finished, I
barely need to test it any more. After settling, it
washes out at 3 litres per minute using minimal
quantities of Eco2Pure, and the result is always
97% or more methyl esters, and if I shake a sample
in a bottle with fresh water, it settles out within
seconds, leaving clear water below and clear
biodiesel on top, no thin white band, and if I PH
test the water, it is nearly always between 7 and
7.5. Any reading outside this means that the
Eco2Pure needs changing, which is a messy but
simple job.
The only failures I ever get now are
when I say “ I wonder what will happen if I
…....” at the start of a batch.
If
you know what you are doing and love DIY, go for it
and build your own. It will give you hours of fun
and frustration. If you are a newcomer and/or just
want good quality biodiesel with the least hassle,
you are unlikely to save money by doing it
yourself. If budget allows, get a ready made
processor from somebody who knows what they are
doing and proves it to you with a personal
demonstration BEFORE you part with any money. No
reputable company would object to that. Although
the cash outlay is more up front, it will be easier
to operate and you can be up and running the next
day, producing usable biodiesel for your car at low
cost per litre. You choose, but in the long run I
know that I would have saved a lot of money by
following my own advice learned the hard way.
And buying a ready made processor does
not spoil our “discovery” fun. There's
loads still out there to experiment with and
discover. After all, some of you, despite having
made biodiesel for years, despite having built and
designed your own processor, and despite having
successfully run your cars on your own fuel for
ages, still have a TAM 105 40 lpm pump attached to
a processor making 100 litre batches, and wonder
why it takes so long to react. Be honest, I bet you
never knew before now that your agitation energy
was too low, did you?
P.S. I have nothing against a Tam
105, in fact I have one and it's brilliant, but I
use mine on the wash cycle. I pump the raw
biodiesel from my processor into a 205 litre
settling tank, where it stands for as long as
possible, but often only a day or so. From there
it is pumped into a 22mm copper pipe leading to a
brass 'T' piece. One leg goes through a 22mm ball
valve back into the settling tank, where it sprays
onto the surface, releasing any last traces of
methanol. The other leg goes through a 22mm ball
valve into the dry wash tower. Adjusting the ball
valves allows me to control the flow rate through
the dry wash tower. I've had the pump for years and
it's still plodding on, long after central heating
pumps have packed in. But put a Tam 105 on a
biodiesel processor handling more than 20 litres of
WVO? Never, ever, ever. If my 110 lpm pump slows
down each time when increasing batch size from 25
litres through 100, 150 then to 180 litres, I dread
to think what happens using a TAM 105 on a 100
litre batch, and I'm pleased that I will never,
ever find out the answer.
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