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Lurgi From Crops to Fuels - Biodiesel 1 Contents Biodiesel from Renewable Resources Biodiesel from Renewable Page The ’Kyoto Protocol’ – which is the Resources United Nations framework convent- ■ Advantages of Biodiesel 2+3 ion on climate change – requires the Transesterification Process introduction of biofuels into the ■ Principle of Process transport fuel market in order to ■ Feedstock reduce greenhouse gas emissions. ■ Yields The ’EU Biofuels Regulation’ urges ■ Final Products the member states to ensure the in- ■ Consumption figures 4+5 crease of the market share of bio- Profitability fuels in the transport fuel market ■ Increased Profitability by from 2% in 2005 to a remarkable Pharmaceutical Glycerine 5.75% in 2010. Produktion 5 Future shortage in petroleum supply Special Features of Lurgi's and surging prices for petroleum Biodiesel Technology 6 based fuels will significantly increase the shift towards the alternative Lurgi's Expertise 6 fuels sector. References Biodiesel will become a vital part of ■ Germany's largest our energy supply and may be used Biodiesel Plant 7 either as a fuel additive mixed in any ratio with biodiesel from renewable resources, a mineral diesel or as a pure product. In either case fuel quality requirements are critical and expectations are rising. Recognizing this trend at an early stage Lurgi, a world-leader in the field of oleochemicals, is able to provide the industry with a multi-purpose technology able to process in principal all vegetable and animal oils and fats. Lurgi has been building biodiesel (methylester) plants for over 15 years and is the marketleader in designing plants to meet the industrial de-mand for higher capacities, improved eco- nomy and better quality – total ca- pacity of plants under design, con- struction and operation amounts to more than 1 million tons per year. 2 Advantages of Biodiesel ■ Reduction of particulates (smoke) emission by approx. 50% ■ Bio-degradable ■ Biodiesel does not contain ■ Closed CO loop benzene or other aromaties 2 ■ Minimum greenhouse ■ Higher engine efficiency and gas emissions durability ■ Sulfur-free ■ Improvement of ignition and lubricity ■ Less dependance on fuels from mineral oils ■ Flash point at approx. 150°C - petroleum diesel at approx. 70°C ■ Non-toxic ■ Safest fuel to store and handle Oils & Fats Block Flow Diagram Biodiesel Production Oil Pretreatment Chemicals Methanol + Transesterification Glycerine Treatment Catalyst Biodiesel G.-W.-Evaporation Washing & Drying Glycerine Distillation and Bleaching Biodiesel Crude Glycerine Glycerine in pharmaceutical ready for use > 80% conc. quality > 99.5% conc. 3 Transesterification Process Flowsheet of the process Reactor 1 Reactor 2 Transesterification Highlights of Lurgi’s Process Oil Methanol Glycerin Cross-Flow Wash (Patented) Column Biodiesel Methanol Recovery Glycerine Catalyst Closed Wash- Glycerin Water Closed Wash- Water water Loop Evaporation water loop Evaporation Glycerin Water Glycerine Water Grude Clycerine Crude Glycerin Principle of Process Feedstock Final Products Transesterification is based on the In principle all edible oils and fats – ■ Biodiesel: E DIN 51606 / EN 14214 chemical reaction of triglycerides vegetable and animal – can be trans- ■ Crude glycerine: with methanol to form methylesters esterified; fatty acids can be ester- British Standard 2621 and glycerine in the presence of an ified. For fuel-specific properties, ■ Pharmaceutical-grade glycerine: alkaline catalyst. This reaction is ef- pretreated oils from rape and sun- EU Pharmacopoeia 99.5 fected in a two-stage mixer-settler flower seeds are preferred in Europe. unit. Transesterification takes place Consumption figures in the mixing section, while the sub- Pretreatment and/or esterification as The consumption figures – without sequent settling section allows for optional process steps are only re- glycerine distillation and bleaching – the separation of methylesters as the quired if the feedstock quality does stated below are valid for the light phase from glycerine water as not meet the following produc-tion of 1 ton of rapeseed the heavy phase. specification: methylester at continuous operation FFA content max. 0.1% and nominal capacity. A subsequent countercurrent wash- Water content max. 0.1% ■ Steam consumption: ing step for the methylester removes Unsaporifiables max. 0.8% approx. 415 kg minute by-product components and Phosphorus content max. 10 ppm ■ Cooling water consumption: 3 gives a biodiesel “ready for use” (∆ t=10 °C) approx. 25 m after the final drying step. Yields ■ Electrical energy:approx. 12 kWh 1,000 kg of dried, degummed and ■ Methanol: approx. 96 kg The surplus methanol contained in deacidified rapeseed oil will give: ■ Catalyst: approx. 5 kg the glycerine water is removed in a ■ Biodiesel: approx. 1,000 kg (Na-Methylate 100%) rectification column, which yields ■ Crude glycerine:approx. 128 kg ■ Hydrochloric acid (37%): methanol in a condition and purity ■ Pharmaceutical-grade glycerine: approx. 10 kg ready for use as a recycle stream to approx. 93 kg ■ Caustic soda (50%): approx. 1.5 kg the process. For further glycerine ■ Technical-grade glycerine: ■ Nitrogen: approx. 1 Nm3 water purification additional steps approx. 5 kg ■ Process water: approx. 20 kg of chemical treatment, evaporation, distillation and bleaching may follow optionally. 4
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