Production system and method

Abstract

In a first aspect, systems and methods for producing biodiesel fuel include a modular production unit incorporated onto a single platform or into a housing for ease of relocatability. The modular production unit preferably includes a mixing unit, a reactor unit, a separation unit, a distillation unit, and a filtering unit, all incorporated onto or into a self-contained platform or housing that is able to be easily relocated. In a second aspect, the modular production unit is combined with additional fixed and / or relocatable components to provide a biodiesel processing plant. In a third aspect, a raw materials processing system and method includes a roller barrel adapted for recovery, transportation, and introduction of recycled oil feedstock into a biodiesel manufacturing process. The raw materials processing system preferably includes a hot box for filtering and heating the raw recycled oil feedstock.

Description

RELATED INFORMATION [0001] This application is a continuation of application Ser. No. 10 / 098,737, the disclosure of which is expressly incorporated herein by reference.FIELD OF THE INVENTION [0002] The invention primarily relates to systems and methods for manufacturing and processing fuels and, more particularly, relates to systems and methods for manufacturing and processing biodiesel fuels comprising a self-contained production unit that is capable of being relocated as needed. BACKGROUND OF THE INVENTION [0003] Biodiesel is the name for a variety of ester-based oxygenated fuels made from vegetable oils, fats, greases, or other sources of triglycerides. It is a nontoxic and biodegradable substitute and supplement for petroleum diesel. Even in blends as low as 20% biodiesel to 80% petroleum diesel (B20), biodiesel can substantially reduce the emission levels and toxicity of diesel exhaust. Biodiesel has been designated as an alternative fuel by the United States Department of Ener...

AI Technical Summary

Benefits of technology

[0014] One challenge for the modular production unit of the present invention was to create an alcohol / catalyst mixer and a separation reactor that could both mix and heat within the space constraints of the modular unit. This is accomplished according to a preferred embodiment of the present invention by replacing the conventional top mounted mixers with a pump driven set of nozzle jets within a hot water jacketed tank. The jets circulate the reactants at a high velocity, and the reactants are drawn from a cone-shaped bottom portion of the tank for recirculation. This creates a central vortex within the reaction tank that allows rapid and complete mixing of the reactants. The pumps are also used for filling and emptying the alcohol / catalyst mixer and the separation reactor. A venturi valve couples the alcohol / catalyst mixer with the separation reactor to allow the constant introduction of the correct proportion of alcohol / catalyst to raw oil.

[0015] Once the reactants are thoroughly mixed the reaction begins and the raw oil begins to separate into biodiesel and glycerin. As the glycerin is formed the reaction approaches equilibrium and begins to slow, and eventually stops before all of the raw oil has been reacted. The conventional practice is to allow the reactant to reach saturation, draw off the glycerin (with excess alcohol), and then rereact the remaining mixture of raw oil and biodiesel. This process generally takes four to six hours. By using the alcohol / catalyst mixer and the separation reactors in the manner provided by the present invention, the process is sped up to occur within two hours. As glycerin is formed it drops to the cone-shaped bottom of the separation reactor. As part of the recirculation of the reactants, the reactants are run through an array, preferably three, of serial centrifuges to separate the glycerin from the raw oil and biodiesel. The raw oil and biodiesel are recirculated to the separation reactor and the glycerin is sent to a continuous flow distillation unit where excess alcohol is removed. The excess alcohol is returned to the alcohol / catalyst mixer, mixed with additional catalyst, and then reintroduced through a venturi coupling into the separation reactor. The entire process is conducted under a constant temperature of just under the boiling point of the alcohol (in the case of methanol, just below 150° F.) to speed up the reaction. By maintaining constant temperature and removal of the glycerin as it is formed, the entire reaction is driven to completion in a much shorter time.

Problems solved by technology

Conventional biodiesel production systems are based upon large, fixed base plants which require expensive capitalization and on site construction.

As a result, current biodiesel production is limited to discrete locations where fixed plants may be constructed.

This results in inefficiencies that may otherwise be obtained by locating a plant near a source of raw materials, or near an end user of the biodiesel product.

Further, the conventional process relies upon batch processing, in which the transesterification reaction proceeds in at least two multi-hour stages and in which the separation processes are not able to be performed continuously.

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