U.S. patent application number 14/113813 was filed with the patent office on 2014-10-02 for biofuel production method and system.
This patent application is currently assigned to GER ENTERPRISES, LLC. The applicant listed for this patent is Arlene Hanson. Invention is credited to Arlis Hanson, Luke Christopher Ice, Richard Lee Peterson, Nicholas Joseph Sever, Anton Angelo Thompkins.
Application Number | 20140290128 14/113813 |
Document ID | / |
Family ID | 47072725 |
Filed Date | 2014-10-02 |
United States Patent
Application |
20140290128 |
Kind Code |
A1 |
Hanson; Arlis ; et
al. |
October 2, 2014 |
BIOFUEL PRODUCTION METHOD AND SYSTEM
Abstract
In an embodiment of the present invention, a renewable energy
fuel is prepared by a process including the steps of: a) providing
a renewable energy feedstock; b) providing an alcohol; c) providing
a catalyst; d) mixing (a), (b), and (c) to form a blend; and e)
homogenizing the blend at a pressure greater than 400
kilogram-force per square centimeter (Kg/cm2).
Inventors: |
Hanson; Arlis; (Bath,
SD) ; Thompkins; Anton Angelo; (Valparaiso, IN)
; Sever; Nicholas Joseph; (Portage, IN) ;
Peterson; Richard Lee; (Aberdeen, SD) ; Ice; Luke
Christopher; (Fort Wayne, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hanson; Arlene |
Bath |
SD |
US |
|
|
Assignee: |
GER ENTERPRISES, LLC
Valparaiso
IN
|
Family ID: |
47072725 |
Appl. No.: |
14/113813 |
Filed: |
April 25, 2012 |
PCT Filed: |
April 25, 2012 |
PCT NO: |
PCT/US12/35025 |
371 Date: |
April 7, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13094502 |
Apr 26, 2011 |
|
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14113813 |
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Current U.S.
Class: |
44/308 ; 44/307;
44/639 |
Current CPC
Class: |
Y02E 50/13 20130101;
Y02E 50/10 20130101; B01J 3/04 20130101; Y02P 30/20 20151101; C10G
2300/1014 20130101; C11C 3/003 20130101; B01J 19/0066 20130101;
C10L 1/02 20130101; C10L 1/19 20130101; C10L 1/026 20130101; B01J
3/02 20130101; C10G 2300/1018 20130101; C10G 3/42 20130101; C10L
1/00 20130101; C10G 1/08 20130101; C10L 1/04 20130101 |
Class at
Publication: |
44/308 ; 44/307;
44/639 |
International
Class: |
C10L 1/00 20060101
C10L001/00; B01J 19/00 20060101 B01J019/00 |
Claims
1. A renewable energy fuel prepared by a process comprising the
steps of: a) providing a renewable energy feedstock; b) providing
an alcohol; c) providing a catalyst; d) mixing (a), (b), and (c) to
form a blend; and e) homogenizing the blend at a pressure greater
than 400 kilogram-force per square centimeter (Kg/cm2).
2. The fuel prepared by the process of claim 1, wherein the
feedstock comprises an animal or vegetable oil, chosen from the
group consisting essentially of beef tallow, pork fat, poultry fat,
oil from soybeans, cottonseeds, canola, rapeseeds, rice bran, flax
seeds, safflowers, cranbe, corn, sunflowers, mustard seeds, palm,
peanuts, coconuts, or other vegetable or animal material, used or
recycled animal or vegetable oils, other biologically derived oils,
oil from annual cover crops, algal oil, biogenic waste
oils/fats/greases, or combinations thereof.
3. The fuel prepared by the process of claim 1, wherein the alcohol
is a short chain alcohol chosen from the group consisting
essentially of one or more monovalent or multivalent alcohols, such
as methanol, ethanol, isopropanol, butanol, trimethylpropane,
glycerols and other polyols or combinations thereof.
4. The fuel prepared by the process of claim 1, wherein the
catalyst comprises a non-ionic surfactant.
5. The fuel prepared by the process of claim 1, wherein the
feedstock is present in an amount of from about 90% to about 99% of
the total weight of the composition.
6. The fuel prepared by the process of claim 1, wherein the alcohol
is present in an amount of from about from about 1% to about 10% of
the total weight of the composition.
7. The fuel prepared by the process of claim 1, wherein the
catalyst is present in an amount of from about from about 0.01% to
about 5% of the total weight of the composition.
8. The fuel prepared by the process of claim 1, wherein the
homogenizing step further comprises a pressure cannon having: a
planar member; and a fluid nozzle disposed in cooperative alignment
with the planar member, the fluid nozzle being configured to
receive a flow of the blend and direct the flow of the blend in a
stream at greater than 400 kilogram-force per square centimeter
(Kg/cm2) towards the planar member and perpendicular to a face of
the planar member, wherein the stream of the blend is homogenized
to generate the Biofuel in response to striking the planar
member.
9. A method of preparing a biofuel comprising the steps of: a)
providing a renewable energy feedstock; b) providing an alcohol; c)
providing a catalyst; d) mixing (a), (b), and (c) to form a blend;
and e) homogenizing the blend at a pressure greater than 400
kilogram-force per square centimeter (Kg/cm2).
10. The method of claim 9, wherein the feedstock comprises an
animal or vegetable oil, chosen from the group consisting
essentially of beef tallow, pork fat, poultry fat, oil from
soybeans, cottonseeds, canola, rapeseeds, rice bran, flax seeds,
safflowers, cranbe, corn, sunflowers, mustard seeds, palm, peanuts,
coconuts, or other vegetable or animal material, used or recycled
animal or vegetable oils, other biologically derived oils, oil from
annual cover crops, algal oil, biogenic waste oils/fats/greases, or
combinations thereof.
11. The method of claim 9, wherein the alcohol is a short chain
alcohol chosen from the group consisting essentially of one or more
monovalent or multivalent alcohols, such as methanol, ethanol,
isopropanol, butanol, trimethylpropane, glycerols and other polyols
or combinations thereof.
12. The method of claim 9, wherein the catalyst comprises a
non-ionic surfactant.
13. The method of claim 9, wherein the feedstock is present in an
amount of from about 90% to about 99% of the total weight of the
composition.
14. The method of claim 9, wherein the alcohol is present in an
amount of from about 1% to about 10% of the total weight of the
composition.
15. The method of claim 9, wherein the catalyst is present in an
amount of from about 0.01% to about 5% of the total weight of the
composition.
16. The method of claim 9, wherein the homogenizing step further
comprises a pressure cannon having: a planar member; and a fluid
nozzle disposed in cooperative alignment with the planar member,
the fluid nozzle being configured to receive a flow of the blend
and direct the flow of the blend in a stream at greater than 400
kilogram-force per square centimeter (Kg/cm2) towards the planar
member and perpendicular to a face of the planar member, wherein
the stream of the blend is homogenized to generate the biofuel in
response to striking the planar member.
17. A system for manufacturing a biofuel, the system comprising: a
feedstock supply; an alcohol supply; a catalyst supply; a mixing
tank in fluid connection with the feedstock supply, alcohol supply,
and catalyst supply, the mixing tank being configured to generate a
mixture of feedstock, alcohol, and catalyst; a pump in fluid
connection with the mixing tank, the pump configured to receive the
mixture from the mixing tank and generate a flow of the mixture;
and a pressure cannon in fluid connection with the pump, the
pressure cannon comprising: a planar member; and a fluid nozzle
disposed in cooperative alignment with the planar member, the fluid
nozzle being configured to receive the flow of the mixture from the
pump and direct the flow of the mixture in a stream at greater than
400 kilogram-force per square centimeter (Kg/cm2) towards the
planar member and perpendicular to a face of the planar member,
wherein the stream of the mixture is homogenized to generate the
biofuel in response to striking the planar member; and a collection
tank in fluid connection with the pressure cannon, the collection
tank configured to collect and store the Biofuel generated by the
pressure cannon.
18. The system according to claim 17, further comprising a
controller configured to control the vegetable oil supply pump, the
alcohol supply pump, and the catalyst supply pump.
19. The system according to claim 17, wherein the mixing tank is a
zero dead volume mixing tank.
20. The system according to claim 17, further comprising a transfer
tank fluidly interposed between the mixing tank and the pressure
cannon.
21. The system according to claim 17, further comprising a
plurality of pressure cannons.
22. The system according to claim 17, further comprising a
plurality of collection tanks, wherein each pressure cannon of the
plurality of pressure cannons includes a respective collection tank
of the plurality of collection tanks.
23. The system according to claim 17, further comprising a
plurality of pumps, wherein each pressure cannon of the plurality
of pressure cannons includes a respective pump of the plurality of
pumps.
24. The system according to claim 17, further comprising a vent in
fluid connection with the collection tank, the vent being
configured to facilitate aeration of the collected biofuel.
25. The system according to claim 17, further comprising an
aeration tank to further aerate the biofuel, the aeration tank
being in fluid connection with the collection tank.
26. The system according to claim 17, further comprising: a
feedstock supply pump; an alcohol supply pump; and a catalyst
supply pump.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This International application claims priority to U.S.
patent application Ser. No. 13/094,502, entitled "Biofuel
Production Method and System" and filed Apr. 26, 2011. That U.S.
application (i) was a continuation-in-part of U.S. patent
application Ser. No. 12/357,804, entitled "Method for Making Diesel
Fuel Additive" and filed Jan. 22, 2009 (now abandoned), which
claimed priority to U.S. Provisional Patent Application No.
61/022,678, entitled "Method for Making Diesel Fuel Additive" and
filed Jan. 22, 2008 (now expired) and (ii) incorporated by
reference the disclosures of those two earlier U.S.
applications.
FIELD OF THE INVENTION
[0002] The present invention generally relates to the manufacture
of fuel. More particularly, the present invention pertains to a
method, device and system for manufacturing renewable biofuel.
BACKGROUND OF THE INVENTION
[0003] Biodiesel is produced via a reaction of vegetable oil or
animal fat with an alcohol (usually methanol) and a catalyst.
Biodiesel is chemically distinct from petroleum diesel and has a
separate ASTM standard (D6751), which specifies the standard for
biodiesel for use as a blend component with petroleum diesel. As
approved by the United States Environmental Protection Agency,
("EPA"), the manufacture of biofuel has involved two conventional
processes: transesterification and hydrotreating.
[0004] Transesterification involves the chemical replacement of
glycerol in a triglyceride with an ester of an alcohol molecule.
The process forms two principal products, fatty acid methyl esters
or FAME, the chemical name for biodiesel, and glycerin. In this
reaction, a vegetable oil or fat reacts with an esterifying agent,
usually an alcohol, with or without a catalyst and with the input
of additional energy, normally at atmospheric pressure. The
reaction time can vary from about 0.5 to about 8 hours depending on
the temperature and whether or not a catalyst is used.
[0005] Thus, transesterification typically proceeds slowly and
generates a great deal of glycerol and some water which must be
removed from the biofuel before it can be used. In addition to
these byproducts, other byproducts such as alcohols, soaps, caustic
agents and the like, may be present as a result of using excess
reactants and catalysts to drive the reaction faster. If not
removed, any of these byproducts may prevent the biofuel from being
burned in a combustion engine or the byproducts may cause harm to
the engine.
[0006] Hydrotreating is a process traditionally used by petroleum
refineries to remove sulfur impurities from diesel fuel. Renewable
diesel produced using this process can either be produced in a
"bio-only" unit that uses only vegetable oils or animal fats as
feedstock or where oils or fats are co-processed with the
distillate fractions (diesel fuel) derived from petroleum. Both
processes produce a mixture of hydrocarbons that has been reported
to meet the ASTM standard for petroleum diesel (D975). The process
also produces propane, carbon dioxide, and water from the oil/fat
feedstock. However, hydrotreating has less desirable cold flow
properties.
[0007] Accordingly, it is desirable to provide a method, device and
system for manufacturing biofuel from renewable resources that is
capable of overcoming the disadvantages described herein at least
to some extent.
SUMMARY OF THE INVENTION
[0008] The foregoing needs are met, to a great extent, by the
present invention, wherein in some embodiments a method, device and
system for manufacturing biofuel from vegetable oil are
provided.
[0009] In an embodiment of the present invention, a renewable
energy fuel is prepared by a process including the steps of: a)
providing a renewable energy feedstock; b) providing an alcohol; c)
providing a catalyst; d) mixing (a), (b), and (c) to form a blend;
and e) homogenizing the blend at a pressure greater than 400
kilogram-force per square centimeter (Kg/cm2).
[0010] In another embodiment of the present invention, a method of
preparing a biofuel includes the steps of: a) providing a renewable
energy feedstock; b) providing an alcohol; c) providing a catalyst;
d) mixing (a), (b), and (c) to form a blend; and e) homogenizing
the blend at a pressure greater than 400 kilogram-force per square
centimeter (Kg/cm2).
[0011] In still another embodiment of the present invention, a
system for manufacturing a Biofuel includes: a feedstock supply; an
alcohol supply; a catalyst supply; a mixing tank in fluid
connection with the feedstock supply, alcohol supply, and catalyst
supply, the mixing tank being configured to generate a mixture of
feedstock, alcohol, and catalyst; a pump in fluid connection with
the mixing tank, the pump configured to receive the mixture from
the mixing tank and generate a flow of the mixture; and a pressure
cannon in fluid connection with the pump, the pressure cannon
comprising: a planar member; and a fluid nozzle disposed in
cooperative alignment with the planar member, the fluid nozzle
being configured to receive the flow of the mixture from the pump
and direct the flow of the mixture in a stream at greater than 400
kilogram-force per square centimeter (Kg/cm2) towards the planar
member and perpendicular to a face of the planar member, wherein
the stream of the mixture is homogenized to generate the Biofuel in
response to striking the planar member; and a collection tank in
fluid connection with the pressure cannon, the collection tank
configured to collect and store the Biofuel generated by the
pressure cannon.
[0012] There has thus been outlined, rather broadly, certain
embodiments of the invention in order that the detailed description
thereof herein may be better understood, and in order that the
present contribution to the art may be better appreciated. There
are, of course, additional embodiments of the invention that will
be described below and which will form the subject matter of the
claims appended hereto.
[0013] In this respect, before explaining at least one embodiment
of the invention in detail, it is to be understood that the
invention is not limited in its application to the details of
construction and to the arrangements of the components set forth in
the following description or illustrated in the drawings. The
invention is capable of embodiments in addition to those described
and of being practiced and carried out in various ways. Also, it is
to be understood that the phraseology and terminology employed
herein, as well as the abstract, are for the purpose of description
and should not be regarded as limiting.
[0014] As such, those skilled in the art will appreciate that the
conception upon which this disclosure is based may readily be
utilized as a basis for the designing of other structures, methods
and systems for carrying out the several purposes of the present
invention. It is important, therefore, that the claims be regarded
as including such equivalent constructions insofar as they do not
depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is block diagram of a biofuel manufacturing system
according to an embodiment of the invention.
[0016] FIG. 2 is a perspective view of a homogenizing cannon
assembly according to the system of FIG. 1.
[0017] FIG. 3 is a cross sectional view of the homogenizing cannon
according to the system of FIG. 1.
[0018] FIG. 4 is a diagram of a system architecture for the biofuel
manufacturing system according to the system of FIG. 1.
[0019] FIG. 5 is a diagram of a system architecture for the control
system suitable for use in the system of FIG. 1.
DETAILED DESCRIPTION
[0020] The present invention provides, in some embodiments, a
biofuel manufacturing system and a method of manufacturing
biofuels. In an embodiment, the invention provides a biofuel
manufacturing system for manufacturing various biofuels such as,
for example, biodiesel, biofuel oil, bio gasoline or petrol, and
the like. In this regard, the term `bio` refers to the biologically
derived nature of at least some portion of the fuel manufactured.
Advantages of certain embodiments of the biofuel manufacturing
system include one or more of: processing a flow of biofuels;
scalability; reducing production costs; reducing byproducts and
costs associated with byproduct removal; increasing production
rate; and the like. As a result of these advantages, the biofuel
manufacturing system may generate a finished biofuel from raw
materials in a relatively compact space and in a relatively short
amount of time as compared to conventional manufacturing
systems.
[0021] In addition, the present biofuel manufacturing system is
readily adaptable to changes in processing procedures and
feedstocks. Chemical processes may be varied according to the
feedstock to improve certain characteristics of the biofuel. These
chemical processes may include the addition of various catalysts,
adjustments to the pH, modulating the temperature and pressure, and
agitation, and the like. Examples of characteristics improved by
various chemical processing include: octane rating; flow
characteristics at various temperatures and pressures; homogeneity;
and the like.
[0022] Depending upon the particular processing being performed,
the biofuel feedstock is subjected to one or more chemical
processes with or without agitation for a predetermined amount of
time, predetermined amount of pressure, and/or at a predetermined
temperature. Due to the flexibility and portability of subunits
that make up the biofuel manufacturing system of the present
invention, the biofuel manufacturing system may be reconfigured
with comparative ease. For example, if, during production, an
additional physical or chemical treatment of the biofuel becomes
necessary, an additional physical or chemical processing subunit of
the biofuel manufacturing system may be integrated. In another
example, speed of production may be easily modified by reducing or
increasing the number of active subunits. In a conventional system,
such a change may require comparatively major re-design and
re-tooling.
[0023] A fuel pathway is defined by three components (1) fuel type;
(2) feedstock; and (3) production process. Essentially, the product
disclosed herein is a "non-ester renewable diesel" rather than a
"biodiesel" as defined by 40 C.F.R. .sctn.80.1401.
[0024] As used herein, the expression "at least one" means one or
more and thus includes individual components as well as
mixtures/combinations.
[0025] As used herein, the term "continuous" refers to the
simultaneous input of reactants and output of products and/or
reactants from a reactor or reaction zone. Furthermore,
"continuous" can be used to describe a system wherein the reactants
and/or products of the system are not divided into batches prior to
entering or immediately after they exit the reactor or separation
units of the system.
[0026] Unless otherwise indicated, all numbers expressing
quantities of ingredients, reaction conditions, and so forth used
in the specification and claims are to be understood as being
modified in all instances by the term "about." Accordingly, unless
indicated to the contrary, the numerical parameters set forth in
the following specification and attached claims are approximations
that may vary depending upon the desired properties sought to be
obtained by the present invention. Other than in the operating
examples, or where otherwise indicated, all numbers expressing
quantities of ingredients and/or reaction conditions are to be
understood as being modified in all instances by the term "about,"
meaning within 10% to 15% of the indicated number.
[0027] A common vegetable-oil-derived fuel, typically used as a
fuel for diesel engines is referred to as "biodiesel." A biodiesel
fuel used as a fuel and not as an additive with a petroleum based
fuel or ethanol, at 100%, is referred to as "B100." If the biofuel
is used as an additive with another fuel, such as diesel fuel or
gas or oil, the biofuel is typically identified by the percentage
of biodiesel present, such as, B5, B20, B30, and so forth.
[0028] As used herein, the terms "oils" and "fats" are chemically
interchangeable, the distinction between such products being that
they are merely distinguished on the basis of their physical state.
To avoid confusion with other types of oils, such as essential oils
or oils derived from petroleum, these products will be identified
to the extent possible as "vegetable or animal oils" or "vegetable
or animal fats" but unless the context clearly indicates otherwise,
a reference to fats and oils should be understood to refer to
vegetable or animal oil components as opposed to petroleum oils. As
used herein, the term "oil" can also encompass any biologically
derived source of tri-, di-, or mono-acylglycerols however
substituted. The term "oil" can encompass, but is not limited to,
beef tallow, pork fat, poultry fat, oil from soybeans, cottonseeds,
canola, rapeseeds, rice bran, flax seeds, safflowers, cranbe, corn,
sunflowers, mustard seeds, palm, peanuts, coconuts, or other
vegetable or animal material, used or recycled animal or vegetable
oils, other biologically derived oils, oil from annual cover crops,
algal oil, biogenic waste oils/fats/greases, or combinations
thereof. In one embodiment, the oil used is a vegetable derived
oil. Preferably, the oil represents from about 90% to about 99% of
the total weight of the composition, more preferably from about 95%
to about 98% of the total weight of the composition, and most
preferably from about 96% to about 97%, including all ranges and
subranges therebetween.
[0029] The alcohol employed to react with the oil can be any
suitable alcohol or blend of alcohols for carrying out the
reaction. Preferably, the alcohol is a short chain alcohol. For
example, the alcohol can include one or more monovalent or
multivalent alcohols, such as methanol, ethanol, isopropanol,
butanol, trimethylpropane, glycerols and other polyols or
combinations thereof. Preferably, the alcohol represents from about
1% to about 10% of the total weight of the composition, more
preferably from about 2% to about 7% of the total weight of the
composition, and most preferably from about 2% to about 4%,
including all ranges and subranges therebetween.
[0030] The catalyst used can include one or more surfactants, such
as nonionic, ionic or partially ionic, anionic, amphoteric,
cationic, zwitterionic surfactants or combinations thereof.
Particularly preferred surfactants include non-ionic surfactants.
Non-limiting non-ionic surfactants include, polyethoxylated and/or
polypropoxylated alkyl phenols, alpha-diols and alcohols,
comprising fatty chains comprising, for example, from 8 to 18
carbon atoms, and the number of ethylene oxide and/or propylene
oxide groups may range from 2 to 50. Further, the non-ionic
surfactant may be chosen, for example, from copolymers of ethylene
oxide and of propylene oxide, condensates of ethylene oxide and/or
of propylene oxide with fatty alcohols; polyethoxylated fatty
amides comprising, for example, from 2 to 30 mol of ethylene oxide,
polyglycerolated fatty amides comprising on average 1 to 5
glycerol, and, for example, 1.5 to 4, glycerol groups;
polyethoxylated fatty amines comprising, for example, from 2 to 30
mol of ethylene oxide; oxyethylenated fatty acid esters of sorbitan
comprising, for example, from 2 to 30 mol of ethylene oxide; fatty
acid esters of sucrose, fatty acid esters of polyethylene glycol,
alkylpolyglycosides, N-alkylglucamine derivatives, and amine oxides
such as (C.sub.10-C.sub.14) alkyl amine oxides and
N-acylaminopropylmorpholine oxides. The catalyst represents from
about 0.01% to about 5% of the total weight of the composition,
more preferably from about 1% to about 3% of the total weight of
the composition, and most preferably from about 1% to about 2%,
including all ranges and subranges therebetween.
[0031] Generally, in an embodiment of the present invention, a
vegetable oil is blended with an alcohol and a catalyst and the
blend is processed through a high pressure pump to achieve a
microemulsion that will not separate under extreme heat or cold
temperatures.
[0032] The invention will now be described with reference to the
drawing figures, in which like reference numerals refer to like
parts throughout. As shown in FIG. 1, a biofuel manufacturing
system ("BMS") 10 includes an inventory of raw materials or supply
station 12, a processing station 14, a product station 16, and a
control station 18. To fluidly connect the various components of
the BMS 10 to one another, the BMS 10 includes one or more supply
lines 20. In addition, the BMS 10 may include a plurality of valves
22-32. The valves 22-32 may include any valve suitable for
modulating the flow of a fluid. A particular example of a suitable
valve includes Tri 750-03-ESP available from Kundinger Controls
Products of Auburn Hills, Mich. More particularly, the valves 22-32
may each include a respective solenoid or other such actuator 34-44
configured to modulate the respective valves 22-32 in response to
signals from a controller such as the control station 18, for
example. A particular example of a suitable actuator includes
Radius ES900 available from Kundinger Controls Products of Auburn
Hills, Mich. However, in other embodiments, the valves 22-32 may be
manually operated. To generate a flow of fluids or otherwise convey
fluids between the various components, the BMS 10 includes a
plurality of pumps 46-54.
[0033] To monitor the flow and/or other parameters of the fluid,
the BMS 10 may include a plurality of sensors 56-68. If present,
the sensors 56-68 may be configured to sense flow speed, volume,
mass, fluid temperature, pressure, and/or the like. A particular
example of a suitable sensor includes Badger ER9 available from
Kundinger Controls Products of Auburn Hills, Mich. The BMS 10 may
include a plurality of control lines 70-74 to communicate between
the control station 18 and the various components of the BMS 10.
For example, the control lines are configured to transmit signals
between the control station 18 and the actuators 34-44, pumps
46-54, and sensors 56-68.
[0034] The supply station 12 is configured to receive, store,
and/or dispense the inventory of the various raw ingredients used
to produce the biofuel. In a particular example, three supply tanks
76, 78, and 80 are included in the supply station 12. However, in
other examples, the supply station 12 may include any suitable
number of supply tanks or containers. In a particular example, the
supply tank 76 is configured to receive, store, and/or dispense a
supply of vegetable oil, the supply tank 78 is configured to
receive, store, and/or dispense a supply of alcohol, and the supply
tank 80 is configured to receive, store, and/or dispense a supply
of catalyst. Of note, while the supply tanks 76-80 are shown as
being the same relative size, the supply tanks 76-80 need not be
the same size but rather, may be any suitable relative or absolute
size and may contain any suitable material to make the biofuel. The
supply tanks 76-80 are fluidly connected to the processing station
14 via the one or more supply lines 20.
[0035] The processing station 14 is configured to generate a
mixture and homogenize the mixture to produce the biofuel. The
processing station 14 includes a mixing tank 82 and a homogenizer
84. The mixing tank 82 includes a mixer 86 configured to agitate or
otherwise mix the contents of the mixing tank 82. The mixer 86 may
be configured to operate in response to signals from the control
station 18. A particular example of a suitable mixer includes
Nettco 5KB-2-SBS available from Kundinger Controls Products of
Auburn Hills, Mich.
[0036] Although shown with supply lines 20 going directly from the
supply tanks 76-80, it should be understood that various amounts of
oil, catalyst or alcohol can be supplied at various times. For
example, there may be instances where only oil and alcohol are
supplied into the mixing tank 82 at first and mixed. The catalyst
can be supplied at a later time. Alternatively, the catalyst and
oil can be supplied first and then alcohol at a later time. Thus,
various combinations are possible and within the scope of the
present invention.
[0037] Depending upon the desired throughput of the system, the
processing station 14 may further include a `buffer` tank (not
shown) disposed between the mixing tank 82 and homogenizer 84. If
included, the buffer tank is configured to receive the mixture from
the mixing tank 82 and dispense the mixture to the homogenizer 84.
In this manner, the mixing tank 82 may be filled again to generate
another batch of the mixture while the previous batch is being
homogenized. Such a configuration allows for continuous operation.
As many buffer tanks as needed can be utilized with this
system.
[0038] The homogenizer 84 is configured to receive the mixture from
the mixing tank 82 or the buffer tank and homogenize this mixture.
In a particular example, the homogenizer 84 includes a pump 88 and
cannon 90. The pump 88 is configured to generate greater than 400
kilogram-force per square centimeter "Kg/cm2" (5,689 pounds per
square inch "psi") of fluid pressure. Preferably, the pump 86 is
configured to generate between about 400 Kg/cm2 to about 700 Kg/cm2
(about 5,689 psi to about 9,956 psi). More preferably, the pump 88
is configured to generate between about 500 Kg/cm2 to about 600
Kg/cm2 (about 7,112 psi to about 8,534 psi). A particular example
of a suitable pump includes General Industries SH30 available from
Kundinger Controls Products of Auburn Hills, Mich.
[0039] FIG. 2 is a side view of the homogenizer 84 assembly
according to the system of FIG. 1. FIG. 3 is a cross-sectional view
of the cannon 90 according to the system of FIG. 1. As shown in
FIGS. 2-3, the cannon 90 includes a body 92, nozzle 94, strike
plate 96, and outlet 98. The nozzle 94 is configured to receive a
flow of the mixture from the pump 88 and direct the flow along a
longitudinal axis of the body 92. The strike plate 96 is a planar
member in cooperative alignment with the nozzle 94. A face of the
strike plate 96 is perpendicularly disposed relative to a stream of
the mixture directed from the nozzle 94. In response to striking
the strike plate 96, frictional heat is generated and the stream of
fluid is heated and subjected to sufficient shear force or `shear
stress` to homogenize the mixture into a biofuel. No external
heating source is required. The outlet 98 is configured to provide
an outlet for the biofuel. Upon exiting the homogenizer 84, the
biofuel may drain or be pumped to the product station 16.
[0040] The product station 16 includes a product tank 100 that is
configured to receive the biofuel from the homogenizer 84 and store
the biofuel. While not shown, the product tank 98 may include a
vent (either powered or unpowered) to vent off excess alcohol or
the like. In addition, the product tank 100 may include an outlet
and/or outlet conduits to convey the biofuel from the product tank
100 to a transport system such as a tanker truck, pipeline, or the
like.
[0041] Returning to FIG. 2, the supply line 20 from the mixing tank
82 (shown in FIG. 1) is fluidly connected to a buffer tank 102. The
buffer tank 102 is configured to provide a buffering or reserve
capacity to reduce cycling of the homogenizer 84 between batches of
mixture. Thereafter, the supply line 20 fluidly connects the buffer
tank 102 with the pump 88. More particularly, the pump 88 includes
a fluid pump 104 driven by a motor 106. The supply line 20 is
configured to fluidly connect the buffer tank 102 with the fluid
pump 104. Also shown in FIG. 2, the motor 106 and thus the
operation of the pump 88 may be modulated by the control station
18.
[0042] Operation of the pump 88 is configured to generate a
pressurized flow of the mixture which is conveyed along a pressure
line 108 to the cannon 90. As described herein, a stream of the
mixture is driven into the strike plate 96 to homogenize the
mixture. Thereafter, the homogenized biofuel drains out from the
cannon 90 via the outlet 98. In an embodiment, the homogenized
biofuel flows into a collection tank 110.
[0043] The collection tank may be configured to provide an initial
venting of the biofuel into the atmosphere or collection device to
dissipate any excess ethanol or other such volatile component not
integrated into the biofuel. In this regard, the collection tank
110 may include a vent which may be powered and/or naturally
aerated. The system may include aeration tanks 112. The aeration
tanks 112 evaporate trace alcohol which is beneficial because the
flashpoint of the final product can be raised during the process. A
higher flash point allows the final product to be transported
easily because it is not deemed flammable and hazardous. The trace
alcohol so aerated can be captured, condensed and re-introduced
into the process from the aeration tanks 112.
[0044] The collection tank 110 may further include the supply line
20 configured to convey the biofuel from the collection tank to the
product tank 100. As shown in FIG. 3, the pressurized flow of the
mixture is provided to the cannon 90 via the pressure line 108.
This flow, denoted with arrows marked A, is directed in a stream
running along a longitudinal axis of the cannon 90 and is driven
into the strike plate 96 at sufficient pressure to homogenize the
mixture. In general, a pressure greater than 400 Kg/cm2 (5,689
pounds per square inch "psi") is sufficient to homogenize the
mixture. Preferably, the pressure is between about 400 Kg/cm2 to
about 700 Kg/cm2 (about 5,689 psi to about 9,956 psi). More
preferably, the pressure is between about 500 Kg/cm2 to about 600
Kg/cm2 (about 7,112 psi to about 8,534 psi). In response to
striking the strike plate 96 at sufficient pressure, a direction of
travel is altered 90.degree. from the longitudinal axis
(perpendicular to the longitudinal axis) and is driven outwardly in
a radial fashion denoted with arrows marked B.
[0045] Without being constrained by any particular theory, this
outward flow from the point of impact generates shear stress within
a zone 114 due to a flow of the fluid closer to the strike plate 96
experiencing relatively greater friction as compared to a flow of
the fluid relatively further from the strike plate 96. The
differential friction across the flow causes differences in the
relative flow rate generating a shear force or shear stress, as
well as heat. This shear stress, together with turbulence of the
flow towards the outlet 98 and heating due to the frictional
forces, is configured to homogenize the mixture into the biofuel.
The homogenized fluid then flows out of the cannon, denoted with
arrows marked C. This process is generally illustrated in FIG. 3 by
the series of arrows A, B, C, beginning at the pressure line 108,
traveling along the longitudinal axis of the cannon 90, striking
the strike plate 96, cascading back along an interior bottom
surface of the cannon 90 and draining down the outlet 98.
[0046] FIG. 4 is a diagram of a system architecture for the biofuel
manufacturing system according to the system of FIG. 1. As shown in
FIG. 4, the BMS 10 may be controlled via the control station 18.
For example, the control station 18 may be configured to send
and/or receive signals from the actuator 34-44, plurality of pumps
46-54, plurality of sensors 56-68, mixer 86, pump 88, and other
such suitable components of the BMS 10. The control station 18 may
include a user interface such as, for example, a keypad 120 and a
display 122. In addition to or alternatively, the user interface
may include touch screen device, indicator lights, dials, buttons,
speakers, and the like.
[0047] The BMS 10 may include a memory 124 configured to provide
data storage for the control station 18. For example, the memory
124 may be configured to store sensor readings, date and time
stamps, a computer readable file 126, and the like. The file 126
may include computer readable lines of code for performing biofuel
production or the like. In addition, the BMS 10 may include a
computer network 128 configured to provide access to a database 130
and/or server 132 and a multitude of other networked devices. In
this regard, the network 128 may include a local area network
(LAN), wide area network (WAN), wireless network, the Internet, and
the like.
[0048] FIG. 5 is a diagram of a system architecture for the control
system suitable for use in the system of FIG. 1. As shown in FIG.
5, the control station 18 includes a processor 144. This processor
144 is operably connected to a power supply 146, memory 148, clock
150, analog to digital converter (A/D) 152, and an input/output
(I/O) port 154. The I/O port 154 is configured to receive signals
from any suitably attached electronic device and forward these
signals to the A/D 152 and/or the processor 144. For example, the
I/O port 154 may receive signals associated with temperature and/or
flow rates from the sensors 56-68 and forward the signals to the
processor 144. If the signals are in analog format, the signals may
proceed via the A/D 152. In this regard, the A/D 152 is configured
to receive analog format signals and convert these signals into
corresponding digital format signals. Conversely, the A/D 152 is
configured to receive digital format signals from the processor
144, convert these signals to analog format, and forward the analog
signals to the I/O port 154. In this manner, electronic devices
configured to receive analog signals may intercommunicate with the
processor 144.
[0049] The processor 144 is configured to receive and transmit
signals to and from the A/D 152 and/or the I/O port 154. The
processor 144 is further configured to receive time signals from
the clock 150. In addition, the processor 144 is configured to
store and retrieve electronic data to and from the memory 148.
Furthermore, the processor 144 is configured to determine signals
operable to modulate and thereby control the actuators 34-44, pumps
46-54 and 88, mixer 86, and various other suitable components.
[0050] In a particular example according to an embodiment of the
invention, the processor 144 is configured to determine an
appropriate amount of fluid to pump from each of the supply tanks
76-80 to generate the mixture. The processor 144 may be configured
to monitor the respective amounts of fluid pumped via the signals
from the sensors 56-60. In addition, the processor 144 may be
configured to determine an amount of time to mix the reagents in
the mixing tank 82 e.g., a completion of a cycle time. These and
other such commands may be stored to the file 126 (shown in FIG. 4)
which may be accessed to execute the computer readable code
disposed therein.
[0051] In another example, the processor 144 may be configured to
supply the catalyst. These reagents are mixed and about 600 parts
alcohol are added and mixed. This mixture may be continually
agitated for about 24 hours. Thereafter, the catalyst solution may
be utilized to generate the biofuel described herein.
[0052] Based on experiments conducted using soybean oil as
feedstock, the following results were obtained. As shown in Table 1
below, the presently disclosed process is more efficient because
there is less land use change (with associated greenhouse gas
emissions) and fewer agricultural sector impacts per BTU of fuel
produced. As shown in Table 2, the inventive process uses less
energy than the soybean biodiesel process, which results in a
reduction in green house gas ("GHG") emissions. Advantageously, the
inventive process does not have onsite emissions because it does
not require onsite combustion of natural gas or other fossil fuels
for process energy. Overall, the inventive process results in
higher fuel production GHG emission impacts compared to the soybean
biodiesel process.
[0053] Compared with soybean biodiesel, the non-ester renewable
diesel disclosed herein is more efficient and has less GHG impacts
related to feedstocks. In the experiments that were conducted, the
fuel type and feedstock were similar to conventional processes such
as transesterification and hydrotreating. The production process
was substantially different. The process disclosed herein uses less
soybean oil in terms of oil input per BTU of fuel produced. Thus,
the amount of soybeans needed in feedstock transport and production
is also reduced. This process also does not produce a co-product
that results in an increase in GHG emissions unlike the soybean
biodiesel production process. The inventive process results in more
fuel produced per amount of raw materials used.
TABLE-US-00001 TABLE 1 Comparison of Agricultural Sector and Land
Use Change Impacts for Soybean Biodiesel and Non-Ester Renewable
Diesel Soybean Non-Ester Biodiesel Renewable Diesel Lifecycle Stage
(g CO2-eq./mmBtu) (g CO2-eq./mmBtu) Domestic Livestock -2,100
-1,980 Domestic Farm Inputs 106 100 and Fertilizer N2O Domestic
Rice Methane -7,950 -7,494 Domestic Land Use Change -8,896 -8,386
International Livestock -6,436 -6,194 International Farm Inputs
5,402 5,199 and Fertilizer N2O International Rice Methane 2,180
2,098 International Land Use 42,543 40,947 Change Total Feedstock
Production 24,848 24,290 Emissions:
TABLE-US-00002 TABLE 2 Comparison of Fuel Production Emissions for
GER Renewable Diesel and Soybean Biodiesel Lifecycle Stage Soybean
Non-Ester (soybean crushing and Biodiesel Renewable Diesel fuel
production) (g CO.sub.2-eq./mmBtu) (g CO.sub.2-eq./mmBtu) On-Site
Emissions 9,486 Upstream (natural gas, 9,312 15,346 catalyst and
electricity production) Co-Product Credit -5,645 0 Total Fuel
Production 13,153 15,346 Emissions:
[0054] Using the BMS 10 system described above, a microemulsion
finished product is created that does not separate under extreme
heat or cold temperatures. The many features and advantages of the
invention are apparent from the detailed specification, and thus,
it is intended by the appended claims to cover all such features
and advantages of the invention which fall within the true spirit
and scope of the invention. Further, since numerous modifications
and variations will readily occur to those skilled in the art, it
is not desired to limit the invention to the exact construction and
operation illustrated and described, and accordingly, all suitable
modifications and equivalents may be resorted to, falling within
the scope of the invention.
* * * * *