French Fry Fuel Sponsored by J.R. Simplot, Co. Conditioning used frying oil for conversion to biodiesel Shane Bird, Marie Stark, Kate Burlingame, Chuck Weatherspoon, John Neal

Design Review Outline Background Accomplishments Problem Definition Remove Particulate Matter Reduction of Water Content from Oil Reduction of FFA Content from Oil Integrated Solution Concepts Project Challenges Budget/Timeline Discussion Questions

Background The J.R. Simplot Company generates 2 million pounds of waste oil each year. Simplot would like to condition the oil and convert it to biodiesel, which would then be returned to Simplot to offset the diesel used in the transportation fleet.

Accomplishments The waste oil generated in production lines forms two waste streams. Team French Fry Fuel has performed numerous tests on the mainstream oil. We determined that it is suitable for conversion to biodiesel.

Problem Statement The secondary waste stream generated, DAF (Dissolved Air Floatation) oil, is an economic drain on Simplot. Our goal is to pretreat both elements of DAF oil, MOP (oil from plant clean-up) and WESP (wet electrostatic precipitator), before sending them to a biodiesel manufacturer. In order to condition the oil, the team will design a system to remove free fatty acids, water, particulates, and other carbon impurities from the used oil to a specification defined by the biodiesel manufacturer. <4% FFA <.1% Water by weight <50-100 micron particulate size

Integrated Solution Test FFA Level Test FFA Level & Water Content Heat Biodiesel Conversion for FFA < 4% Water Removal Filter Esterification for FFA > 4% Falling Film Evaporator Flash Evaporator Self Cleaning Paper Filters Bag Filter BD20 Beads Sulfuric Acid

Particulate Removal: Bag Filter Advantages: Easy to clean. Filters large amounts of particulates. Low start-up cost. Disadvantages: Large particulate may push through filter bags. Manual maintenance. Easy Access Filter-Bag Housings Stainless Steel Felt Filter Bags http://www.mcmaster.com/

Particulate Removal: Self-Cleaning Paper Filter Advantages: Self cleaning. Filters large amounts of particulates. Low maintenance. Disadvantage: High Start-up cost. Continuous Paper Filter http://www.heatandcontrol.com/product.asp?pid=46

FFA Reduction: Acid Esterification Using Sulfuric Acid Sulfuric acid (catalyst) is dissolved in methanol, then added to the oil While the reaction takes place continuous dewatering must also occur Advantages: Can be batch or continuous Higher removal of FFA Make more fuel out of high FFA feedstock Disadvantages: Must remove water continuously for high yields Potential hazardous chemical, methanol utilized Increased chemical cost

FFA Reduction: BD20 This emerging technology uses the same principles as acid esterification. Advantages: Treats oils with FFA ranging from 0.5 to 100% Fast reaction time High conversion efficiency Can treat oils with low levels of water Fewer toxic chemicals Disadvantages Availability issues Unknown cost

Water Reduction: Falling Film Evaporator Falling film evaporators work by allowing a film of the liquid to flow down the tubes of the heat exchanger. Advantages: Will remove high water content from fluids Works with low temperature differences. Disadvantages: Complicated design Requires higher heat A: Product B: Vapor C: Concentrate D: Heating Steam E: Condensate 1: Head 2: Calandria 3: Calandria, Lower part 4: Mixing Channel 5: Vapor Separator www.niroinc.com/evaporators_crystallizers/falling_film_evaporators.asp

Flash Evaporation (Water Removal) Flash evaporation is the vaporization of a saturated liquid (in this case oil) as it undergoes a pressure reduction through a small orifice or throttling device. The oil is heated and then sent via a pump to the feed inlet where it goes through a reduction in pressure. The applied heat and reduced pressure converts the water in the oil to a vapor. Note: If the oil has greater than 5% water in it then multiple evaporators may be needed to remove that water to an acceptable level.                                   http://en.wikipedia.org/wiki/Flash_evaporation

Recommended Treatment Process Water Heated Agitated Tank Q (1) DAF Oil To Blue Sky (2) Water Q P Evaporator Filter System (3) P P P Particles Esterification P Sample taken for Water content and FFA testing Send to Blue Sky if FFA ≤ 4% FFA Test for Water and FFA content Methanol Recovery

Cost for Full Scale Design Process Unit Cost/Unit Est. Cost Sulfuric Acid 5 190mL Bottles $32.00 BD-20 Bag Filter Ea. $1200 $1500 Self Cleaning $100,000 Flash Evaporator $50,000 Falling Film $60,000

Design Challenges Further lab analysis of the WESP and MOP oils will allow us to determine a treatment plan. Hazardous chemicals near food processing plant. Effective cost analysis. Bench-top model.

Timeline Snapshot Day ……………….Nov. 30 2007 Semester End Report Due…Dec. 11 2007 Winter Break…………………Dec. 14 2007 Spring Semester Begins…….Jan. 9 2007 2nd Design Review………….Feb. ?? 2008 Final Report Due…………….May ?? 2008 Engineering Expo……………April 25 2008

Ideas, Comments, or Suggestions Questions? Ideas, Comments, or Suggestions