U.S. patent application number 11/112600 was filed with the patent office on 2006-10-26 for biofuel conversion process.
Invention is credited to Norikazu Nakamura.
Application Number | 20060236595 11/112600 |
Document ID | / |
Family ID | 36617145 |
Filed Date | 2006-10-26 |
United States Patent
Application |
20060236595 |
Kind Code |
A1 |
Nakamura; Norikazu |
October 26, 2006 |
Biofuel conversion process
Abstract
A process, method, apparatus and materials for efficient
conversion of waste vegetable oils into biofuel that does not use
methanol as a reactant or catalyst. The resulting biofuel is mixed
with kerosene or heavy oil to form a stable diesel fuel grade fuel
that is mixable with diesel fuel. In addition, the process and
apparatus are also applicable to the conversion of virgin vegetable
oils and other waste or virgin oils, such as used motor oil, into
fuels or fuel additives.
Inventors: |
Nakamura; Norikazu;
(Shimajiri-gun, JP) |
Correspondence
Address: |
Squire, Sanders & Dempsey L.L.P
14th Floor
801 S. Figueroa Street
Los Angeles
CA
90017-5554
US
|
Family ID: |
36617145 |
Appl. No.: |
11/112600 |
Filed: |
April 22, 2005 |
Current U.S.
Class: |
44/307 |
Current CPC
Class: |
Y02E 50/13 20130101;
C10G 1/08 20130101; Y02E 50/10 20130101; C10G 1/086 20130101; C10L
1/026 20130101 |
Class at
Publication: |
044/307 |
International
Class: |
C10L 1/00 20060101
C10L001/00 |
Claims
1. A biofuel production process comprising the steps of: pumping a
desired quantity of vegetable based oil into a mixing tank;
preparing a catalyst powder composition having an aluminum sludge
zeolite material (Na.sub.2O, SiO.sub.2, H.sub.2O) and a composition
of calcium oxide, sodium monoxide, aluminum oxide, silicon dioxide
and water in the formula 0.75CaO, 0.2Na.sub.2O, Al.sub.2O.sub.3,
2SiO.sub.2, 4.5H.sub.2O; blending a mixture of catalyst powders and
absorption powders; mixing the catalyst powders and aborption
powders into the vegetable based oil in the mixing tank; heating
the mixture in the tank to a temperature in the range of between
about 60 and 80 degrees centigrade for a period of 40 to 60
minutes; pumping the mixture through a filter system to remove
substantially all of the particulate and powdered materials and
obtain a filtered biofuel having neutral pH and an energy content
in excess of 9000 calories/gram.
2. The biofuel production process of claim 1, wherein the catalyst
powders preferably include 25 to 35 weight percent of the aluminum
sludge zeolite material Na.sub.2O, nSiO.sub.2, xH.sub.2O and 65 to
75 weight percent 0.75CaO, 0.2Na.sub.2O Al.sub.2O.sub.3,2SiO.sub.2,
4.5H.sub.2O.
3. The biofuel production process of claim 1, wherein the
absorption powders are 78 to 82 percent silicon dioxide
(SiO.sub.2), 11 to 13 percent aluminum oxide (Al.sub.2O.sub.3), 2.5
to 3.5 percent iron oxide (Fe.sub.2O.sub.3), 3 to 4.5 percent
magnesium oxide (MgO), and 0.5 to 1 percent calcium oxide
(CaO).
4. The biofuel production process of claim 2, wherein the
absorption powders are: silicon dioxide (SiO.sub.2), aluminum oxide
(Al.sub.2O.sub.3), iron oxide (Fe.sub.2O.sub.3), magnesium oxide
(MgO), and calcium oxide (CaO).
5. The biofuel production process of claim 1, wherein the catalyst
powders and the absorption powders comprise: a catalyst composition
powder having 25 to 35 weight percent of an aluminum sludge zeolite
material and 65 to 75 weight percent of 0.75CaO, 0.2Na.sub.2O
Al.sub.2O.sub.3,2SiO.sub.2, 4.5H.sub.2O; and an absorption
composition powder having predominantly silicon dioxide
(SiO.sub.2), and up to about 20 weight percent combined of aluminum
oxide (Al.sub.2O.sub.3), iron oxide (Fe.sub.2O.sub.3), magnesium
oxide (MgO), and calcium oxide (CaO).
6. The biofuel production process of claim 5, wherein the powders
are formed to a particle size of less than 500 .mu.m.
7. The biofuel production process of claim 5, wherein the mixture
is pumped through a filter system having a filter media with a
filter size of 150 mesh.
8. The biofuel production process of claim 5 wherein the ratio of
catalyst powders to absorption powders is in the range of between
about 1:2 and 1:6.
9. The biofuel production process of claim 5 wherein the amount of
catalyst powders required for processing 100 liters of vegetable
oil is in the range of between about 450 and 550 grams.
10. The biofuel production process of claim 5 wherein the amount of
absorption powders required for processing 100 liters of vegetable
oil is in the range of between about 1 kilogram to 6 kilograms.
11. The biofuel production process of claim 1, further comprising
the step of separating solids from the vegetable based oils in a
separator prior to pumping the desired quantity into the mixing
tank.
12. The biofuel production process of claim 1, further comprising:
pumping the filtered biofuel to a blending tank; pumping a
hydrocarbon based fuel selected from kerosene and fuel oil into the
blending tank; blending the biofuel and the hydrocarbon based fuel
with an absorption powder composition in a ratio of between 1 and 3
kilograms of absorption powder to 200 liters of blended fuel for a
time period of 30 minutes to 60 minutes; and filtering the blended
composition through a high pressure filtration system to remove
substantially all of the absorption powder to yield a blended
biofuel.
13. The biofuel production process of claim 12, further comprising:
filtering the blended biofuel through a filter having a filter size
of 250 to 300 mesh.
14. A biofuel production process comprising the steps of: pumping a
desired quantity of vegetable based oil into a mixing tank;
preparing catalyst powders and absorption powders, wherein the
catalyst powders comprise a catalyst composition powder having 25
to 35 weight percent of an aluminum sludge zeolite material, 65 to
75 weight percent of a composition of calcium oxide, sodium
monoxide, aluminum oxide, silicon dioxide and water in the formula
0.75CaO, 0.2Na.sub.2O Al.sub.2O.sub.3,2siO.sub.2, 4.5H.sub.2O; and
the absorption powders comprise an absorption composition powder
having up to 82 weight percent of silicon dioxide (SiO.sub.2), up
to 12 weight percent of aluminum oxide (Al.sub.2O.sub.3), up to 3.5
weight percent of iron oxide (Fe.sub.2O.sub.3), up to 4.5 weight
percent of magnesium oxide (MgO), and up to 1 weight percent of
calcium oxide (CaO); mixing the catalyst powders and absorption
powders into the vegetable based oil in the mixing tank; heating
the mixture in the tank to a temperature in the range of between
about 60 and 80 degrees centigrade for a period of 40 to 60
minutes; pumping the mixture through a filter system to remove
substantially all of the particulate and powdered materials and
obtain a filtered biofuel.
15. A reaction powder composition for aiding the conversion of
vegetable oils to biofuel, comprising: a catalyst composition
powder having 25 to 35 weight percent of an aluminum sludge zeolite
material Na.sub.2O, SiO.sub.2, H.sub.2O, and 65 to 75 weight
percent of a composition of calcium oxide, sodium monoxide,
aluminum oxide, silicon dioxide and water in the formula 0.75CaO,
0.2Na.sub.2O Al.sub.2O.sub.3,2SiO.sub.2, 4.5H.sub.2O; and an
absorption composition powder having silicon dioxide (SiO.sub.2),
aluminum oxide (Al.sub.2O.sub.3), iron oxide (Fe.sub.2O.sub.3),
magnesium oxide (MgO), and calcium oxide (CaO).
16. The reaction powder of claim 15 wherein the powders are formed
to a particle size of less than 200 .mu.m.
17. The reaction powder of claim 15 wherein the ratio of catalyst
composition powder to absorption composition powder is in the range
of between about 1:2 and 1:6.
18. The reaction powder of claim 15 wherein the ratio of catalyst
powder to absorption powder is in the range of between about 1:2
and 1:4.
19. The reaction powder of claim 15 wherein the amount of catalyst
composition powder required for processing 100 liters of vegetable
oil is in the range of between about 450 and 550 grams.
20. The reaction powder of claim 15 wherein the amount of
absorption powder required for processing 100 liters of vegetable
oil is in the range of between about 1 kilogram to 6 kilograms.
21. A waste vegetable oil conversion slurry comprising: waste
vegetable oil; a catalyst composition powder; an absorption
composition powder; said waste vegetable oil, catalyst composition
powder and absorption composition powder mixed together in a ratio
of 100 liters oil to between about 400 and 600 grams catalyst
composition powder and between about 800 and 3,000 grams absorption
composition powder.
22. The waste vegetable oil conversion slurry of claim 21 wherein
the catalyst composition powder and the absorption composition
powder comprise a catalyst composition powder having an aluminum
sludge zeolite material (Na.sub.2O, SiO.sub.2, xH.sub.2O), and a
composition of calcium oxide, sodium monoxide, aluminum oxide,
silicon dioxide and water in the formula 0.75CaO, 0.2Na.sub.2O
Al.sub.2O.sub.3,2SiO.sub.2, 4.5H.sub.2O; and an absorption
composition powder having 75 to 85 weight percent of silicon
dioxide (SiO.sub.2), 10 to 14 weight percent of aluminum oxide
(Al.sub.2O.sub.3), 2 to 4 weight percent of iron oxide
(Fe.sub.2O.sub.3), 2 to 5 weight percent of magnesium oxide (MgO),
and 0.5 to 2 weight percent of calcium oxide (CaO).
23. A fuel production process comprising the steps of: pumping a
desired quantity of mineral or petroleum based oil into a mixing
tank; preparing a catalyst powder composition having an aluminum
sludge zeolite material (Na.sub.2O, SiO.sub.2, H.sub.2O) and a
composition of sodium monoxide, silicon dioxide and water in the
formula: Na.sub.2O, nSiO.sub.2, xH.sub.2O; preparing an absorption
powder composition; mixing the catalyst powders and aborption
powders into the oil in the mixing tank; heating the mixture in the
tank to a temperature in the range of between about 60 and 80
degrees centigrade for a period of 40 to 60 minutes; pumping the
mixture through a filter system to remove substantially all of the
particulate and powdered materials and obtain a filtered fuel
having an energy content in excess of 9000 calories/gram.
24. The fuel production process of claim 23, wherein the catalyst
powders preferably include 25 to 35 weight percent of the aluminum
sludge zeolite material (Na.sub.2O, nSiO.sub.2, xH.sub.2O) and 65
to 75 weight percent Na.sub.2O, nSiO.sub.2, xH.sub.2O.
25. The fuel production process of claim 24, wherein the absorption
composition powder is 75 to 85 weight percent of silicon dioxide
(SiO.sub.2), 10 to 14 weight percent of aluminum oxide
(Al.sub.2O.sub.3), 2 to 4 weight percent of iron oxide
(Fe.sub.2O.sub.3), 2 to 5 weight percent of magnesium oxide (MgO),
and 0.5 to 2 weight percent of calcium oxide (CaO).
26. The fuel production process of claim 23 wherein the ratio of
catalyst powders to absorption powders is in the range of between
about 1:2 and 1:6.
27. The fuel production process of claim 23 wherein the amount of
catalyst powders required for processing 100 liters of oil is in
the range of between about 450 and 550 grams.
28. The fuel production process of claim 23 wherein the amount of
absorption powders required for processing 100 liters of oil is in
the range of between about 1 kilogram to 6 kilograms.
29. A reaction powder composition for aiding the conversion of
contaminated petroleum oils to fuel grade oil, comprising: a
catalyst composition powder having 25 to 35 weight percent of an
aluminum sludge zeolite material (Na.sub.2O SiO.sub.2 H.sub.2O),
and 65 to 75 weight percent of a composition of sodium monoxide,
silicon dioxide and water in the formula: Na.sub.2O, nSiO.sub.2,
xH.sub.2O; and an absorption composition powder having silicon
dioxide (SiO.sub.2), aluminum oxide (Al.sub.2O.sub.3), iron oxide
(Fe.sub.2O.sub.3), magnesium oxide (MgO), and calcium oxide
(CaO).
30. The reaction powder of claim 29, wherein the absorption
composition powder includes in excess of 70 weight percent silicon
dioxide (SiO.sub.2).
Description
BACKGROUND OF THE INVENTION
[0001] Biofuel is a type of fuel made using non-petroleum based
oils converted to allow combustion within power plants and engines
as a replacement for heavy oils and diesel fuel. Biofuels have
desirable burning characteristics and are derived from renewable
resources. For example, biofuels may be derived from vegetable oils
processed from crops.
[0002] Vegetable oils are used extensively in food preparation in
restaurants, hotels, hospitals and other large institutions. The
use of vegetable oils in food preparation generates substantial
waste product that must be appropriately disposed of. Processing of
these waste vegetable oils into biofuel thus serves two beneficial
purposes, creation of a clean and environmentally friendly fuel
source and the elimination of waste disposal requirements.
[0003] To understand the scope of the potential use of the present
invention it is beneficial to appreciate the extent of the
generation of waste vegetable oils in our society. As an example,
the city of Okinawa, Japan, the home of the inventor, has about 1.2
million people. It is estimated that Okinawa generates about
400,000 liters of waste vegetable oils, primarily tempura cooking
oils, every month, but that amount may be only about 1/2 of the
actual annual production. Of the known amount, approximately 90% is
recoverable and available for reprocessing. In addition, Okinawa
has a very large US military base having 50,000 military and
civilian personnel that is estimated to generate about 100,000
liters of waste vegetable oil per month.
[0004] There are several known processes relating to the field of
conversion of waste vegetable oils into biofuel. In one practice,
the waste vegetable oils are gathered and stored in large drums,
for example 55 gallon drums. The waste vegetable oils are allowed
to sit for thirty days so that the sediments in the waste oil
settle to the bottom of the container. After the settling process,
the top clarified oil is removed for processing in a column
catalytic reaction chamber while the bottom layer of oil having
retained sediments and oil are sent for disposal. This process is
inefficient as it requires extensive storage periods and there is
still a significant amount of sediment contaminated waste oil that
is sent for disposal.
[0005] It is also a common process in the conversion of vegetable
oils, whether virgin or waste oils, to use methanol as a reactant
or catalyst. The methanol based processes have as an advantage that
the resulting biofuel can be used in engines without being mixed
with other fuels. A volume of vegetable oil is mixed with a
solution of Methanol and Sodium hydroxide. Approximately 80% of the
oil volume becomes fuel, and byproducts are glycerin, fatty
acids.
[0006] Engines running on biodiesel sometimes register an increase
in Nitrous Oxide (NO.sub.x) emissions. The range of increasing in
NO.sub.x emissions resulting from biodiesel can be anywhere between
1-15% but is generally around 5%. The complete lack of sulfur in
biodiesel fuel allows the use of powerful NO.sub.x breaking
catalysts that had been unusable.
[0007] The present invention is directed to a process, method,
apparatus and materials for efficient conversion of waste vegetable
oils into biofuel that does not use methanol as a reactant or
catalyst. Engines running on biofuel register a decrease in Nitrous
Oxide (NO.sub.x) emissions.
[0008] However, the methanol based processes result in a biofuel
that does not mix well with other fuels, such as diesel fuel, so a
small quantity of methanol derived biofuels must be mixed with
other fuels, such as diesel fuel for automobiles.
[0009] It would therefore be beneficial to have a biofuel
conversion process that does not require the storage and settling
of solids from the waste oils and that does not waste a percentage
of the oil contaminated with sediments, and that results in a
biofuel that can be mixed in a tank with other fuels such as diesel
fuel.
INVENTION SUMMARY
[0010] The present invention is directed to a process, method,
apparatus and materials for efficient conversion of waste vegetable
oils into biofuel that does not use methanol as a reactant or
catalyst. The resulting biofuel is mixed with kerosene or heavy oil
to form a stable diesel fuel grade fuel that is mixable with diesel
fuel. In addition, the process and apparatus are also applicable to
the conversion of virgin vegetable oils and other waste or virgin
oils, such as used motor oil, into fuels or fuel additives. In the
process, the waste oils are mixed with a blend of catalyst and
absorption powders in a tank and heated to about 80 degrees
centigrade for 40 to 60 minutes. The composition is then passed
through a filter to remove the added powders, any sediments and
certain contaminates in the oil including most carbon solids, as
well as certain fatty acids and constituents of the waste oil. The
mixing and filtering process clarifies the resulting biofuel and
enhances the energy content from 4,000 to 5,000 calories/gram to
9,000 to 10,000 calories/gram.
[0011] The clarified biofuel resulting from vegetable oils may then
be blended with kerosene and filtered through the filter bed
containing the removed sediments from the first filtering process
or a powder mixture of absorption powders is added to the blended
biofuel and kerosene, mixed for 40 to 60 minutes and then filtered.
A similar process can be used to recover and generate fuel grade
oil from used or waste motor oil, with a resulting product that can
be mixed with the biofuel derived from vegetable oils as a
replacement for the kerosene additive to produce a light grade or
heavy grade fuel oil.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 schematically depicts the processing apparatus of the
present invention.
[0013] FIG. 2 schematically depicts an alternate configuration of
the processing apparatus of the present invention.
[0014] FIG. 3 schematically depicts the fuel blending filter
assembly and process used with the apparatus of FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] FIG. 1 schematically depicts a basic biofuel conversion
apparatus 10 according to a first aspect of the present invention.
The apparatus 10 includes an oil tank 20 that is either a large
storage tank or plurality of storage drums. Oil from tank 20 is
routed via pipe 22 and pump 24 to a catalyst tank 30. The catalyst
tank 30 includes a mixing apparatus 32, for example a motor 34,
shaft 36 and impeller 38. The lower section of the catalyst tank 30
includes a heating assembly 40, for example a steam heat exchange
system. The catalyst tank 30 also includes a temperature sensor 42
and may include a level sensor 44. The temperature sensor 42 is
connected to a controller 46 that controls the pump 24 and the
timing of the process as well as the temperature control for the
heating assembly 40.
[0016] Upon completion of a reaction period in the catalyst tank
30, the mixture is delivered via a pipe 50 to pump 52. The output
of pump 52 is directed to a pipe 54. Pipe 54 delivers the mixture
to a high pressure filter assembly 60. An air compressor 56
provides compressed air via pipe 50 to a junction valve 58 in pipe
54 upstream of the filter assembly 60. The operations of the pump
52 and the compressor 56 are controlled by the controller 46. The
air compressor 56 is used at the end of a filtering process step to
force oils in the pipes and falter assembly 60 through the filter
in assembly 60.
[0017] The high pressure filter 60 filters the mixture from the
catalytic tank 30 through a filter media 62. The high pressure
filter 60 may include a plurality of filter chambers assembled in
series and fed via an axial flow path aligned with the inlet
connection to pipe 54. Preferably, the filter media 62 has a 150
mesh fiberglass filter although a range about this mesh size is
potentially applicable.
[0018] The primary output of high pressure filter 62 is provided to
pipe 70. A secondary output of high pressure filter 60 caused by
leakage along the edges of the filter media 62 is captured in a
tray 64 and delivered via pipe 66 to pump 68 which preferably
directs the secondary output back to the inlet of the high pressure
filter 60.
[0019] Pipe 70 from the high pressure filter 62 is connected to a
valve 72 that directs the flow to a pipe 74 or recirculation pipe
76. The output of pipe 74 is a fuel combination tank 80. The output
from recirculation pipe 76 is a return into the catalyst tank
30.
[0020] The fuel combination tank 80 includes a mixing assembly 82,
including a motor 84 driving a shaft 86 having an impeller 88. In
fuel combination tank 80, the reacted and filtered oil from the
high pressure filter 60 is blended with a base fuel, either
kerosene or light oil (heating oil). An absorption powder
composition may also be added to the blend to enhance the chemical
bonding of the blend and to remove additional contaminants such as
ash and carbon particles.
[0021] After a sufficient retention and mixing period in the fuel
combination tank 80, the blend is routed through high pressure
filter 60, or a different high pressure filter of essentially the
same design, which filters out the absorption powder from the
blend. The output of the high pressure filter 60 after filtering
the blend is directed to a product tank 90.
[0022] FIG. 2 schematically depicts a second more advanced biofuel
conversion apparatus 100 according to a second aspect of present
invention. Apparatus 100 includes oil tank 110 that is a large oil
tank or plurality of storage drums. Oil from tank 110 is routed via
pipe 112 to a pump 114 and the output of pump 114 is directed to
pipe 116 having a control valve 118. Pipe 116 directs oil to a
centrifugal separator 120. The separator 120 has an outlet to pipe
122 and waste outlet to waste 124. The separator 120 includes a
motor 126 driving a centrifugal impeller assembly 128, to separate
particulate matter from the oil in the centrifugal separator
120.
[0023] Pipe 122 delivers the cleaned oil to a holding tank 130. Oil
from the holding tank 130 is pumped via pump 132 and pipe 134 into
a catalytic mixing tank 140. The catalytic mixing tank 140 includes
a motor driven mixing assembly 142 with temperature sensor 144 and
level sensor 146 similar to that described above for FIG. 1.
Further, the catalytic mixing tank 40 includes a heating assembly
148, for example a steam heat exchange system, to heat materials in
the catalytic mixing tank 140.
[0024] Catalytic mixing tank 140 is also configured to receive
powders from powder tank 150 via pipe 152 and auger screw feed 154.
The output of mixing tank 140 is directed to a pipe 160 to a high
pressure pump 170. The high pressure pump delivers the mixture via
pipe 172 to a high pressure filter assembly 180. Pipe 172
preferably also includes pressure sensor 174 and a junction valve
176 with junction valve 176 also being connected to an air
compressor 178 for cleaning the pipes and filters at the end of a
batch.
[0025] The high pressure filter assembly 180 is configured similar
to that of high pressure filter assembly 60 of FIG. 1. Accordingly,
the high pressure filter assembly 180 includes a plurality of
filter chambers 182 and filter media 184 to separate particulates
and powder materials from the mixed oil composition passing
therethrough. The outlet product from high pressure filter assembly
180 is delivered via pipe 190 to a secondary filter assembly 194.
The secondary filter assembly 194 includes a directional valve 196
to separate the flow to one of two filters 198. Each of the filters
198 includes a paper filter having a 250 to 300 mesh filter media.
The output side of each of filters 198 is directed to a pipe 200 to
deliver the filtered fuel to a storage tank 220.
[0026] The high pressure assembly 180 also produces a secondary
output to a tray 202. The flow from the tray 202 is directed
through pipe 204 to a pump 206. The output of pump 206 is directed
to pipe 208. Pipe 208 terminates in a directional valve 210 which
separate the flow into one of two pipes 212 each having a filter
214. Each filter 214 includes a paper filter media having a mesh
size of 250 to 300. The output of the filters 214 is directed to a
pipe 216 which delivers the output to the storage tank 220.
[0027] FIG. 3 depicts the blending system for blending the
processed oil with a base fuel such as kerosene or light oil. The
process starts with the storage tank 220 having filtered processed
oil from the system of FIG. 2. The system also includes a fuel tank
222 for containing kerosene or light oil. Each of the tanks 220 and
222 are configured to deliver oil or fuel via pipes 224 and 226,
respectively, to a catalytic blending tank 230. Optionally, a high
pressure filter may be included in pipe 224 to filter out any
retained particulate matter. Also, as depicted, there may be two
catalytic blending tanks 230 to allow for multiple batch
processing.
[0028] The blending tank 230 includes a mixing assembly 232 having
a motor 234 having a shaft 236 driving impeller 238. The blending
tank 230 may also include level sensor 240 and temperature sensor
242 to provide signals to a system controller 244 that monitors the
level and temperature of the blending composition. The blending
tank 230 may also receive powdered materials from the powder tank
246, delivering powders via a pipe 248 to the catalytic blending
tank 230.
[0029] The blended output from the blending tank 230 is delivered
via a pipe 250 to a high pressure pump 260. The output of the high
pressure pump 260 is delivered via a pipe 262 to a high pressure
filter assembly 270. The pipe 262 preferably includes a pressure
sensor 264 and a junction valve 266, the junction valve 266 also
being connected to receive pressurized air from a compressor 268
used to clean out the pipes and high pressure filter assembly
270.
[0030] The blended composition is delivered to the high pressure
filter assembly 270 to remove powder composition and particulate
matter from the blend. The output of the high pressure filter
assembly 270 is directed to a pipe 280 which delivers the output to
a filter assembly 290. The filter assembly 290 includes a pair of
filters 292 that may be used sequentially as discussed above with
respect to the filter assembly 198. The filters 292 include paper
filter media having a 250 to 300 mesh filter media. The output of
the filter assembly 290 is directed to a biofuel tank 300.
[0031] The high pressure filter tank assembly 270 may also have a
secondary output captured by a tray 272 and delivered to a pump 274
via a pipe 276. The output from pump 274 is directed to filter
assembly 278 having a pair of filters 282, operated sequentially.
Filter assembly 278 has an output pipe 284 delivering the filtered
fuel mixture to biofuel tank 300.
[0032] The biofuel conversion process utilizing either the
apparatus of FIG. 1 or FIG. 2 relies on the use of a catalytic
material and absorption material composition. The catalytic
materials are blended and grounded to fine or super fine powder
having a particle size less than 500 .mu.m and preferably having a
particle size of less than 100 .mu.m. The powdered catalytic
materials are mixed with vegetable oil or waste vegetable oil in
the catalytic tanks. The catalytic powders are preferably: 25 to 35
weight percent of an aluminum sludge zeolite material (Na.sub.2O,
SiO.sub.2, H.sub.2O) and, either 65 to 75 weight percent of a
composition of calcium oxide, sodium monoxide, aluminum oxide,
silicon dioxide and water in the formula 0.75CaO, 0.2Na.sub.2O,
Al.sub.2O.sub.3, 2SiO.sub.2, 4.5H.sub.2O for processing vegetable
oils, or 65 to 75 weight percent of sodium monoxide, silicon
dioxide and water in the formula: Na.sub.2O, nSiO.sub.2, xH.sub.2O,
for processing mineral or petroleum based oils.
[0033] In addition to the powdered catalytic materials, the powder
composition added to the catalytic mixing tank includes powdered
absorption materials, preferably selected from the group consisting
of one or more of the following materials, with the preferred
composition including each of the materials in the relative weight
percentages indicated below: [0034] 79.6 to 82 percent Silicon
Dioxide (SiO.sub.2), [0035] 11.6 to 12 percent Aluminum Oxide
(Al.sub.2O.sub.3), [0036] 2.7 to 3.1 percent Iron Oxide
(Fe.sub.2O.sub.3), [0037] 3.3 to 4.1 percent Magnesium Oxide (MgO),
and [0038] 0.7 to 0.9 percent Calcium Oxide (CaO).
[0039] While the process may not require all of these constituent
component absorption powders, the best results have been obtained
using all of these absorption powders. Moreover, while the narrow
ranges above have been found to be effective an appropriate range
for each of the component materials is 75 to 85 weight percent of
silicon dioxide (SiO.sub.2), 10 to 14 weight percent of aluminum
oxide (Al.sub.2O.sub.3), 2 to 4 weight percent of iron oxide
(Fe.sub.2O.sub.3), 2 to 5 weight percent of magnesium oxide (MgO),
and 0.5 to 2 weight percent of calcium oxide (CaO).
[0040] Further, it has been found that a preferred composition
contains a catalyst composition powder consisting of: thirty weight
percent of the aluminum sludge zeolite material, and 70 weight
percent of Na.sub.2O, nSiO.sub.2, xH.sub.2O, or 70 weight percent
of 0.75CaO, 0.2Na.sub.2O Al.sub.2O.sub.3,2SiO.sub.2, 4.5H.sub.2O;
and an absorption composition powder consisting of: 80.8 weight
percent of silicon dioxide (SiO.sub.2), 11.8 weight percent of
aluminum oxide (Al.sub.2O.sub.3), 2.9 weight percent of iron oxide
(Fe.sub.2O.sub.3), 3.7 weight percent of magnesium oxide (MgO), and
0.8 weight percent of calcium oxide (CaO).
[0041] As described above, the powders forming the ionic exchange
or catalytic materials include an aluminum sludge zeolite. This
aluminum sludge zeolite material may be processed to increase
surface porosity by known methods such as an acid wash, and then
cleaned with a calcium wash to leave a deposit of calcium within
the porosity of the zeolite.
[0042] In processing the vegetable oils in the processing system
described above, the amount of catalytic powder for processing each
100 liters of vegetable oil is 250 to 750 grams with a preferred
range of 450 to 550 grams. For most processes, however, it has been
found that an adequate amount of catalytic powder without excess or
waste is 500 grams for 100 liters of vegetable oil. By comparison,
the amount of the absorption powder for 100 liters of vegetable oil
is in a range of 1 to 2 kilograms for a resulting dark oil or a
range up to 3 kilograms to produce a light or more clarified oil.
For these processes, a preferred range for the amount powders to
yield a dark oil having a higher carbon content would be 1.5
kilograms of absorption powder to 100 liters of process oil to 3
kilograms of absorption powder used to produce a very clear or
clarified oil. Adding in excess of 3 kilograms is not necessary and
leads to excess usage and waste of the absorption powders.
[0043] In the catalytic mixing tank, the powders in the amounts
described above are blended into the waste or virgin vegetable oils
and mixed for a period of 40 to 60 minutes as the mixture is heated
to a reaction temperature of 60.degree. C. to 80.degree. C. and,
preferably, at the upper end of this range such that the
temperature is controlled to between 78.degree. to 80.degree. C. by
the heat exchange assembly and the controller. It is also preferred
that the material be maintained at the reaction temperature for at
least 20 minutes within the 40 to 60 minute interval.
[0044] Within the high pressure filter assemblies described above,
the materials are processed at a pressure of approximately 0.5 MPa
through the filter media. The materials are processed at an initial
flow rate of approximately 90 liter per minute in a fresh filter
media although the processing rate will be reduced with the build
up of a filter cake on the filter media. It is preferred that
materials be recirculated at the beginning of any filtering
process, in particular if a new filter media has been installed in
the high pressure filter assembly. The recirculation of the initial
processed product is beneficial to wet the filter media and to
build a cake of powder including catalytic powder and absorption
powder on the surface of the filter media. It is preferred that the
thickness of the cake be 2 to 3 mm before the filter oil is routed
to the fuel combination tank 80 or tank 220. The filter media can
be used to process 2 to 3 batches of waste oil before the filter
requires cleaning, so the cake build up on the surface of the
filter media and within the high pressure filter may be
substantial. A cake buildup of 2 to 4 cm in thickness thus may
increase the effectiveness of the filter process.
[0045] While fatty acids retained in waste vegetable oils may not
be removed by the filter media in the high pressure filter
assembly, once the cake develops on the surface of the filter media
then it is believed that at least a portion of the fatty acid from
the vegetable oil can be trapped in the cake and removed from the
processed biofuel. In this process, the absorption materials may
allow fatty acids to combine to be of a size that can be retained
either by the cake or by the filter media in the filtering
step.
[0046] When the filtered oil after the first processing stage is
blended with kerosene or light oil, the absorption powders as
discussed above may be added to and mixed with the blend in a range
of approximately 1 kilogram of absorption powder to 200 liters of
combined base oil and kerosene. However, for a process which is
going to be filtered through a filter bed that has not been primed
by prior filtering of the foregoing powders in the first stage,
then preferred the range of absorption powders to 200 liters of
fuel would be from 1 to 3 kilograms. By comparison, if the blended
materials are to be filtered through a high pressure filter
assembly that has previously being used to filter either a mixture
or blend from the processes described above, and the filter has not
been cleaned, then the preferred range of absorption powder would
be 0 to 3 kilograms per 200 liters of combined processed oil or
kerosene.
[0047] It has been found that waste vegetable oil processed
according to the foregoing assembly and method provides a biofuel
component having the following properties: TABLE-US-00001 pH 7.0
Flash point, PMCC 214.0.degree. C. Kinematic Viscosity, 40.degree.
C. 42.42 mm.sup.2/s Pour Point -7.5.degree. C. Carbon (mass %) 0.31
Water 810 ppm Ash (mass %) 0.002 Sulfur (mass %) 0.0002 Density,
15.degree. C. 0.9270 g/cm.sup.3 Calorie 39,310 J/g
[0048] The biofuel produced from waste vegetable oil utilizing the
foregoing technology is stable and, when once mixed with the
kerosene or light oil it can be combined with other diesel fuels or
light oils to be burned in an engine or combustion process without
chemical separation or decomposition. In addition, the pH of the
biofuel is neutral and the biofuel has an energy content that is
consistent with the energy content of other fuels which leads to
the biofuel being stable when combined with other fuels.
[0049] When processing the blended oil and kerosene through the
high pressure filter assembly, the blended composition may not
require absorption powder if the high pressure filter assembly
includes substantial cake deposits on the surface of the filter
media.
[0050] By the process according to the present invention, the waste
oil can be processed to remove particulates, substantially all, if
not all carbon, certain fatty acids, and other contaminates. In
addition, the pH of a waste oil is neutralized to a pH of
approximately 7.0, which occurs because of compounds both within
the catalytic powders and the first three absorption powders.
[0051] The catalytic function of the catalytic powders increases or
ionizes oils to increase energy content and combustibility and
allow blending with kerosene or light oils. In addition, by the
process of mixing both catalytic powders and absorption powders in
the mixing tank, the steps necessary to process waste oil into
biofuel are combined and the processing time for a batch to pass
through the entire process and system of the present invention may
take less than two hours to per batch. Each batch can be scalable
within the foregoing system so that a small facility could process
a batch 100 liters while a large facility could process a batch of
several thousand liters in each of the tanks.
[0052] While the present invention is particularly useful in
processing and cleaning waste vegetable oil, the process is equally
applicable to virgin vegetable oils to convert these virgin oils to
biofuels or biofuel additives. Further, the apparatus described
above may be used to process petroleum based oil, such as used
motor oil, to convert the petroleum oil into a fuel grade oil or
fuel additive. To process petroleum oils, the same process steps
are carried out. However, the powdered catalytic materials for
petroleum based oils include 65 to 75 weight percent sodium
monoxide, silicon dioxide and water in the formula: Na.sub.2O,
nSiO.sub.2, xH.sub.2O, mixed with 25 to 35 weight percent aluminum
sludge zeolite for processing mineral or petroleum based oils.
[0053] When the high pressure filter assembly has been used to
process at least one and up to three or four batches, the filter
media may be cleaned to remove the cake build up. The byproduct
material in the cake build up primarily consists of the catalytic
powders and the absorption powders as well as carbon, particulates,
fatty acids, and other contaminants as well as small amounts of
oil. This byproduct material may be mixed with cement powder and
water and molded to form bricks or other configurations which may
be used for paving and construction materials. It has been found
that a mixture of 75% byproduct and 25% cement powder is sufficient
to form a stable and hardened brick. Other blends and ratios of
byproduct to cement or byproduct and binder materials can be used
so as to form useful construction materials. Accordingly, all
products and byproducts of the process according to this invention
are either useful biofuels or used as construction products.
Alternatively, the byproduct from the filter media may be used as a
fertilizer and soil conditioner, as opposed to being formed into
hardened materials, as the materials contained in the byporoduct
materials are primarily mineral compositions and organic
materials.
[0054] From the foregoing detailed description, it will be evident
that there are a number of changes, adaptations and modifications
of the present invention which come within the understanding of
those skilled in the art. The scope of the invention includes any
combination of the elements from the different species or
embodiments disclosed herein, as well as subassemblies, assemblies,
and methods thereof. However, it is intended that all such
variations not departing from the spirit of the invention be
considered as within the scope of the invention, and that the
invention is interpreted by the proper scope of the appended
claims.
* * * * *